94C09_XTS2500_BSM XTS Series/XTS2500 Basic Service Manual 6881094C09 B XTS2500

User Manual: -XTS Series/XTS2500 Basic service manual 6881094C09-B

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XTS™2500

XTS™1500

MT 1500

700 - 800 MHz

Digital Portable Radios

Basic Service Manual

Foreword

This manual covers all models of the ASTRO™ Digital XTS 2500® Portable Radio, unless otherwise specified. It includes

all the information necessary to maintain peak product performance and maximum working time, using the pass/fail service

approach. This basic level of service is typical of some local service centers, self-maintained customers, and some

distributors.

Included in this manual are: radio specifications for the 700/800 MHz frequency bands; a general description of ASTRO

Digital XTS 2500 models; recommended test equipment, service aids, and tools; radio alignment procedures; fundamental

disassembly/reassembly procedures; and general maintenance recommendations.

For details on the operation of the radio, or board or component-level troubleshooting, refer to the applicable manuals,

available separately. To help you with your selection, a list is provided under “Related Publications” at the front of this

manual.

Safety

Before operating an ASTRO XTS 2500 Radio, please read the RF energy awareness information and operating instructions

in the Product Safety and RF Exposure booklet enclosed with your radio (Motorola Publication part number 68P81095C98)

to ensure compliance with RF energy exposure limits.

Manual Revisions

Changes which occur after this manual is printed are described in “FMRs.” These FMRs provide complete information on

changes, including pertinent parts list data.

Computer Software Copyrights

The Motorola products described in this manual may include copyrighted Motorola computer programs stored in

semiconductor memories or other media. Laws in the United States and other countries preserve for Motorola certain

exclusive rights for copyrighted computer programs, including, but not limited to, the exclusive right to copy or reproduce

in any form the copyrighted computer program. Accordingly, any copyrighted Motorola computer programs contained in

the Motorola products described in this manual may not be copied, reproduced, modified, reverse-engineered, or

distributed in any manner without the express written permission of Motorola. Furthermore, the purchase of Motorola

products shall not be deemed to grant either directly or by implication, estoppel, or otherwise, any license under the

copyrights, patents or patent applications of Motorola, except for the normal non-exclusive license to use that arises by

operation of law in the sale of a product.

i

Table of Contents ➠

List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

Related Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii

Commercial Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

Limited Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ix

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Portable Radio Model Numbering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii

Specifications for 700 MHz/800 MHz Radios. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiv

ASTRO Digital XTS 2500 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

ASTRO XTS 1500/MT 1500 Model Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv

1 - Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Notations Used in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Radio Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

FLASHport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 - Basic Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Introduction to This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preventive Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cleaning External Plastic Surfaces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Handling Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 - Basic Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

General Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Analog Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Transmitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

ASTRO Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

RF Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

VOCON Basic Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 - Recommended Test Equipment and Service Aids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Recommended

Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Field Programming Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

5 - Performance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Introduction to This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Display Radio Test Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Entering Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

RF Test Mode (Display Radio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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ii

Control Top and Keypad Test Mode (Display Radio). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Non-Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Entering Non-Display Radio Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

RF Test Mode (Non-Display Radio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Control Top and Keypad Test Mode (Non-Display Radio) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

6 - Radio Alignment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Radio Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Transmit Power Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Transmit Deviation Balance Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Transmit Deviation Limit Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Front End Filter Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Procedure for 700 MHz Frequencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Procedure for 800 MHz Frequencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Procedure for UHF/VHF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Bit Error Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Bit Error Rate Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Transmitter Test Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Definition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Transmitter Test Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

7 - XTS 2500/XTS 1500/MT 1500 Exploded View and Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

XTS 2500/XTS 1500/MT 1500 Model I Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

XTS 2500 Model II Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

XTS 2500 Model III Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

8 - Disassembly/Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Introduction to This Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Attach the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Remove the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Attach the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Remove the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Attach the Belt Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Remove the Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Universal Connector Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Remove the Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Attach the Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Remote Speaker Microphone Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Remove the Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Attach the Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Radio Disassembly—Detailed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Required Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Front Cover from Chassis Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Chassis Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Backup Battery Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Keypad and Keypad/Option Board Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Display Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Speaker, Microphone, and Universal Connector Flex Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

PTT Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Radio Reassembly—Detailed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

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PTT Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Keypad and Keypad Option Board Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Display Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Speaker, Microphone, and Universal Connector Flex Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Chassis Assembly Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Backup Battery Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Chassis and Front Cover Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

9 - Radio-Level Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Introduction to This Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Power-Up Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Operational Error Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

10 - Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Antennas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Audio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Headsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Earpieces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Remote Speaker Microphones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Surveillance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Belt Clips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Carrying Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chargers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Charger Mounting Kits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Enhanced and Multi-Unit Line Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Table of Contents

iv

List of Figures

v

List of Figures

Figure 1. XTS 2500 Overall Block Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Figure 2. Receiver Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 3. RF Block Diagram (Power and Control Omitted) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 4. Radio Alignment Test Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Figure 5. Tuner Menu Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Figure 6. Typical Softpot Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Figure 7. Radio Information Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Figure 8. Reference Oscillator Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Figure 9. Transmit Power Alignment Screen (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Figure 10. Transmit Deviation Balance Alignment Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Figure 11. Transmit Deviation Limit Alignment Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Figure 12. Front End Filter Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 13. Bit Error Rate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Figure 14. Transmitter Test Pattern Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Figure 15. Attaching the Antenna . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 16. Removing the Antenna. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Figure 17. Step 1, Attaching the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 18. Step 2, Attaching the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 19. Step 1, Removing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 20. Step 2, Removing the Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Figure 21. Attaching the Belt Clip. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Figure 22. Removing the Belt Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Figure 23. Removing the Universal Connector Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 24. Attaching the Universal Connector Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Figure 25. Removing the RSM Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 26. Step 1, Attaching the RSM Adapter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

List of Figures

vi

Figure 27. Step 2, Attaching the RSM Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Figure 28. Knob Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 29. Chassis Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Figure 30. Chassis Separation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Figure 31. Unlatching the Flex Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Figure 32. Removing the Main Board from the Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Figure 33. Remove the Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 34. Retainer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Figure 35. Keypad Retainer and Boards Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Figure 36. Display Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Figure 37. Speaker-Microphone Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Figure 38. PTT Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Figure 39. Lock Retainer Catches to Radio Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Figure 40. Reassemble the Backup Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Figure 41. Fastening the Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

List of Tables

vii

List of Tables

Table 1.ASTRO XTS 2500 Basic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Table 2.Local Oscillator and First IF Frequencies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Table 3.Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Table 4.Service Aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Table 5.Initial Equipment Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Table 6.Front-Panel Access Test-Mode Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Table 7.Test Frequencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Table 8.Test Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Table 9.Receiver Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Table 10.Transmitter Performance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Table 11.Reference Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Table 12.Transmit Power Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Table 13.Model I Exploded View Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Table 14.Model II Exploded View Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Table 15.Model III Exploded View Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Table 16.Front Cover from Chassis Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Table 17.Chassis Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Table 18.Backup Battery Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Table 19.Keypad and Keypad/Option Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Table 20.Display Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Table 21.Speaker, Microphone, and Universal connector Flex Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Table 22.PTT Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Table 23.Power-Up Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Table 24.Operational Error Code Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Table 25.Receiver Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Table 26.Transmitter Troubleshooting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Related Manuals

viii

Related Manuals

ASTRO XTS 2500 Digital Portable Radio Model I User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68P81094C04

ASTRO XTS 2500 Digital Portable Radio Model II User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 68P81094C05

ASTRO XTS 2500 Digital Portable Radio Model III User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 68P81094C06

ASTRO XTS 2500 Digital Portable Radio Detailed Service Manual. . . . . . . . . . . . . . . . . . . . . . . . . 68P81094C10

ASTRO XTS 1500 Digital Portable Radio Model 1 User Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P04113J52

ASTRO MT 1500 Analog Portable Radio Model 1 User Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68P04113J71

ix

Commercial Warranty ➠

Limited Warranty

MOTOROLA COMMUNICATION PRODUCTS

I. What This Warranty

Covers And For How

Long

MOTOROLA INC. (“MOTOROLA”) warrants the MOTOROLA manufactured

Communication Products listed below (“Product”) against defects in material and

workmanship under normal use and service for a period of time from the date of purchase

as scheduled below:

Motorola, at its option, will at no charge either repair the Product (with new or

reconditioned parts), replace it (with a new or reconditioned Product), or refund the

purchase price of the Product during the warranty period provided it is returned in

accordance with the terms of this warranty. Replaced parts or boards are warranted for the

balance of the original applicable warranty period. All replaced parts of Product shall

become the property of MOTOROLA.

This express limited warranty is extended by MOTOROLA to the original end user

purchaser only and is not assignable or transferable to any other party. This is the complete

warranty for the Product manufactured by MOTOROLA. MOTOROLA assumes no

obligations or liability for additions or modifications to this warranty unless made in

writing and signed by an officer of MOTOROLA. Unless made in a separate agreement

between MOTOROLA and the original end user purchaser, MOTOROLA does not warrant

the installation, maintenance or service of the Product.

MOTOROLA cannot be responsible in any way for any ancillary equipment not furnished

by MOTOROLA which is attached to or used in connection with the Product, or for

operation of the Product with any ancillary equipment, and all such equipment is expressly

excluded from this warranty. Because each system which may use the Product is unique,

MOTOROLA disclaims liability for range, coverage, or operation of the system as a whole

under this warranty.

ASTRO Digital XTS2500 Portable Units One (1) Year

Product Accessories One (1) Year

Commercial Warranty

x

II. General Provisions This warranty sets forth the full extent of MOTOROLA'S responsibilities regarding the

Product. Repair, replacement or refund of the purchase price, at MOTOROLA's option, is

the exclusive remedy. THIS WARRANTY IS GIVEN IN LIEU OF ALL OTHER

EXPRESS WARRANTIES. IMPLIED WARRANTIES, INCLUDING WITHOUT

LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE, ARE LIMITED TO THE DURATION OF THIS

LIMITED WARRANTY. IN NO EVENT SHALL MOTOROLA BE LIABLE FOR

DAMAGES IN EXCESS OF THE PURCHASE PRICE OF THE PRODUCT, FOR ANY

LOSS OF USE, LOSS OF TIME, INCONVENIENCE, COMMERCIAL LOSS, LOST

PROFITS OR SAVINGS OR OTHER INCIDENTAL, SPECIAL OR CONSEQUENTIAL

DAMAGES ARISING OUT OF THE USE OR INABILITY TO USE SUCH PRODUCT,

TO THE FULL EXTENT SUCH MAY BE DISCLAIMED BY LAW.

III. State Law Rights SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF

INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LIMITATION ON HOW LONG

AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION OR

EXCLUSIONS MAY NOT APPLY.

This warranty gives specific legal rights, and there may be other rights which may vary

from state to state.

IV. How To Get

Warranty Service

You must provide proof of purchase (bearing the date of purchase and Product item serial

number) in order to receive warranty service and, also, deliver or send the Product item,

transportation and insurance prepaid, to an authorized warranty service location. Warranty

service will be provided by Motorola through one of its authorized warranty service

locations. If you first contact the company which sold you the Product, it can facilitate your

obtaining warranty service. You can also call Motorola at 1-888-567-7347 US/Canada.

V. What This Warranty

Does Not Cover

A) Defects or damage resulting from use of the Product in other than its normal and

customary manner.

B) Defects or damage from misuse, accident, water, or neglect.

C) Defects or damage from improper testing, operation, maintenance, installation,

alteration, modification, or adjustment.

D) Breakage or damage to antennas unless caused directly by defects in material

workmanship.

E) A Product subjected to unauthorized Product modifications, disassemblies or repairs

(including, without limitation, the addition to the Product of non-Motorola supplied

equipment) which adversely affect performance of the Product or interfere with

Motorola's normal warranty inspection and testing of the Product to verify any

warranty claim.

F) Product which has had the serial number removed or made illegible.

G) Rechargeable batteries if:

•any of the seals on the battery enclosure of cells are broken or show evidence of

tampering.

•the damage or defect is caused by charging or using the battery in equipment or

service other than the Product for which it is specified.

H) Freight costs to the repair depot.

Commercial Warranty

xi

I) A Product which, due to illegal or unauthorized alteration of the software/firmware in

the Product, does not function in accordance with MOTOROLA's published

specifications or the FCC type acceptance labeling in effect for the Product at the time

the Product was initially distributed from MOTOROLA.

J) Scratches or other cosmetic damage to Product surfaces that does not affect the

operation of the Product.

K) Normal and customary wear and tear.

VI. Patent And Software

Provisions

MOTOROLA will defend, at its own expense, any suit brought against the end user

purchaser to the extent that it is based on a claim that the Product or parts infringe a United

States patent, and MOTOROLA will pay those costs and damages finally awarded against

the end user purchaser in any such suit which are attributable to any such claim, but such

defense and payments are conditioned on the following:

A) that MOTOROLA will be notified promptly in writing by such purchaser of any

notice of such claim;

B) that MOTOROLA will have sole control of the defense of such suit and all

negotiations for its settlement or compromise; and

C) should the Product or parts become, or in MOTOROLA's opinion be likely to

become, the subject of a claim of infringement of a United States patent, that such

purchaser will permit MOTOROLA, at its option and expense, either to procure for

such purchaser the right to continue using the Product or parts or to replace or modify

the same so that it becomes noninfringing or to grant such purchaser a credit for the

Product or parts as depreciated and accept its return. The depreciation will be an equal

amount per year over the lifetime of the Product or parts as established by

MOTOROLA.

MOTOROLA will have no liability with respect to any claim of patent infringement which

is based upon the combination of the Product or parts furnished hereunder with software,

apparatus or devices not furnished by MOTOROLA, nor will MOTOROLA have any

liability for the use of ancillary equipment or software not furnished by MOTOROLA

which is attached to or used in connection with the Product. The foregoing states the entire

liability of MOTOROLA with respect to infringement of patents by the Product or any parts

thereof.

Laws in the United States and other countries preserve for MOTOROLA certain exclusive

rights for copyrighted MOTOROLA software such as the exclusive rights to reproduce in

copies and distribute copies of such Motorola software. MOTOROLA software may be

used in only the Product in which the software was originally embodied and such software

in such Product may not be replaced, copied, distributed, modified in any way, or used to

produce any derivative thereof. No other use including, without limitation, alteration,

modification, reproduction, distribution, or reverse engineering of such MOTOROLA

software or exercise of rights in such MOTOROLA software is permitted. No license is

granted by implication, estoppel or otherwise under MOTOROLA patent rights or

copyrights.

VII. Governing Law This Warranty is governed by the laws of the State of Illinois, USA.

Commercial Warranty

xii

Notes

xiii

Specifications ➠

Portable Radio

Model

Numbering

System

Position 1 - Type of Unit

H = Hand-Held Portable

Positions 2 & 3 - Model Series

Position 4 - Frequency Band

Less than 29.7MHz

29.7 to 35.99MHz

36 to 41.99MHz

42 to 50MHz

66 to 80MHz

74 to 90MHz

Product Specific

136 to 162MHz

146 to 178MHz

174 to 210MHz

190 to 235MHz

336 to 410MHz

403 to 437MHz

438 to 482MHz

470 to 520MHz

Product Specific

764 to 870MHz

825 to 870MHz

896 to 941MHz

1.0 to 1.6GHz

1.5 to 2.0GHz

Values given represent range only; they are

not absolute.

Position 5 - Power Level

0 to 0.7 Watts

0.7 to 0.9 Watts

1.0 to 3.9 Watts

4.0 to 5.0 Watts

5.1 to 6.0 Watts

6.1 to 10 Watts

Position 6 - Physical Packages

RF Modem Operation

Receiver Only

Standard Control; No Display

Standard Control; With Display

Limited Keypad; No Display

Limited Keypad; With Display

Full Keypad; No Display

Full Keypad; With Display

Limited Controls; No Display

Limited Controls; Basic Display

Limited Controls; Limited Display

Rotary Controls; Standard Display

Enhanced Controls; Enhanced Display

Low Profile; No Display

Low Profile; Basic Display

Low Profile; Basic Display, Full Keypad

Position 7 - Channel Spacing

1 = 5kHz

2 = 6.25kHz

3 = 10kHz

4 = 12.5kHz

5 = 15kHz

6 = 20/25kHz

7 = 30kHz

9 = Variable/Programmable

Typical Model Number:

Position:

Position 8 - Primary Operation

Conventional/Simplex

Conventional/Duplex

Trunked Twin Type

Dual Mode Trunked

Dual Mode Trunked/Duplex

Trunked Type I

Trunked Type II

FDMA* Digital Dual Mode

TDMA** Digital Dual Mode

Single Sideband

Global Positioning Satellite Capable

Amplitude Companded Sideband (ACSB)

Programmable

* FDMA = Frequency Division Multiple Access

** TDMA = Time Division Multiple Access

Position 9 - Primary System Type

Conventional

Privacy Plus

Clear SMARTNET

Advanced Conventional Stat-Alert

Enhanced Privacy Plus

Nauganet 888 Series

Japan Specialized Mobile Radio (JSMR)

Multi-Channel Access (MCA)

CoveragePLUS

MPT1327* - Public

MPT1327* - Private

Radiocom

Tone Signalling

Binary Signalling

Phonenet

Programmable

Secure Conventional

Secure SMARTNET

* MPT = Ministry of Posts and Telecommunications

Position 10 - Feature Level

1 = Basic

2 = Limited Package

3 = Limited Plus

4 = Intermediate

5 = Standard Package

6 = Standard Plus

7 = Expanded Package

8 = Expanded Plus

9 = Full Feature/

Programmable

Position 11 - Version

Version Letter (Alpha) - Major Change

Position 12 -

Unique Model Variations

C = Cenelec

N = Standard Package

Positions 13 - 16

SP Model Suffix

123 4 5 6 7 8 9 10111213141516

H46 U CH 9 P W 7 A N S P 0 1

46 = XTS 2500

66 = XTS 1500

67 = MT 1500

A

B

C

D

F

G

H

J

K

L

M

=

=

=

=

=

=

=

=

=

=

=

P

Q

R

S

T

U

V

W

Y

Z

=

=

=

=

=

=

=

=

=

=

A

B

C

D

E

F

=

=

=

=

=

=

A

B

C

D

E

F

G

H

J

K

L

M

N

P

Q

R

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

A

B

C

D

E

F

G

H

J

K

L

M

P

=

=

=

=

=

=

=

=

=

=

=

=

=

A

B

C

D

E

F

G

H

J

K

L

M

N

P

Q

W

X

Y

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

=

MAEPF-27327-A

Specifications

xiv

Specifications for 700 MHz/800 MHz Radios

All specifications are per Telecommunications Industries Association TIA-603 unless otherwise noted

GENERAL RECEIVER TRANSMITTER

FCC ID:

700/800 MHz: AZ489FT5804

Temperature Range:

Operating: –30°C to +60°C

Storage: –40°C to +85°C

Power Supply: Nickel-Cadmium Battery (NiCd)

or Nickel-Metal-Hydride Battery (NiMH)

Battery Voltage

Nominal: 7.5 Volts

Range: 6 to 9 Volts

Transmit Current Drain (Typical): 1250mA

Receive Current Drain (Rated Audio): 220mA

Standby Current Drain: 70mA

Recommended Battery:

High-Capacity NiCd: NTN9815

or Ultra-High-Capacity NiMH: NTN9858

or High-Capacity NiCd FM: NTN9816*

or Ultra–High-Capacity NiMH FM: NTN9857*

Optional FM (Factory Mutual) Battery:

* FM Intrinsically Safe: Class I, II, III

Dimensions

Height x Width x Depth

Radio Less Battery: 6.0" x 2.3" x 1.5"

With NiCd Ultra-High Cap.: 6.0" x 2.3" x 2.0"

With NiMH Ultra-High Cap.: 6.0" x 2.3" x 2.0"

Weight

Radio Less Battery: 11.0 oz.

With NiCd Ultra-High Capacity: 20.0 oz.

With NiMH Ultra-High Capacity: 20.5 oz.

Frequency Range:

700 MHz: 764 to 767; 773 to 776 MHz

800 MHz: 851 to 870 MHz

Quieting Sensitivity (typical) (20dBQ): 0.23µV

Usable Sensitivity (typical)

(12dB SINAD): 0.25µV

Intermodulation (typical): –74dB

Selectivity (typical)

(25kHz Channel): –72dB

(12.5kHz Channel): –63dB

Spurious Rejection (typical): –75dB

Frequency Stability

(–30+60°C; 25°C reference): 1.5ppm

Rated Audio: 500mW

FM Hum and Noise (typical)

(25kHz channel): –47dB

(12.5kHz channel): –40dB

Distortion (At Rated Audio; typical): 2.5%

Channel Spacing: 12.5/20/25 kHz

RF Power

806 - 870 MHz: 3 Watts

764 - 806 MHz: 2.5 Watts

Frequency Range:

700 MHz: 764 to 767; 773 to 776; 794 to 797; 803

to 806 MHz

800 MHz: 806 to 824; 851 to 870 MHz

Frequency Stability (typical)

(–30 to +60°C; 25°C ref.): 1.5ppm

Emission (typical conducted): -75dBc<1GHz

FM Hum and Noise (typical)

(25 kHz channel): –43dB

(12.5 kHz channel): –40dB

Distortion (typical): 2%

Modulation Limiting: 25 kHz chnls ±5.0kHz

20 kHz chnls ±4.0kHz

12.5 kHz chnls ±2.5kHz

Emissions Designators: 16K0F3E,11K0F3E,

8K10F1D, and 8K10F1E

Specifications

xv

ASTRO Digital XTS 2500 Model Chart

Notes:X=Item Included

ASTRO XTS 1500/MT 1500 Model Chart

Notes:X=Item Included

MODEL NUMBER DESCRIPTION

H46UCC9PW5AN 700/800 MHz, 1-3 Watts, ASTRO Digital XTS 2500 Model I

H46UCF9PW6AN 700/800 MHz, 1-3 Watts, ASTRO Digital XTS 2500 Model II

H46UCH9PW7AN 700/800 MHz, 1-3, Watts ASTRO Digital XTS 2500 Model III

ITEM NUMBER DESCRIPTION

XXX 1505579Z01 Cover, Dust, Accessory Connector

XXX 4385665D01 Adapter, Remote Speaker Microphone

XXX NTN9815 Hi Capacity NiCd Battery

XXX NAF5037 1/2 Wave Whip Antenna, 800 MHz

XXX HLN6853 2.250 inch Belt Clip

XNTN9637 Front Cover Kit, Model I

XNTN9638 Front Cover Kit, Model II

XNTN9639 Front Cover Kit, Model III

XXX NUF6541 RF/VOCON Board Kit

X6881094C04 User’s Guide, Model I

X6881094C05 User’s Guide, Model II

X6881094C06 User’s Guide, Model III

MODEL NUMBER DESCRIPTION

H66UCC9PW5AN 700/800 MHz, 1-3 Watts, ASTRO Digital XTS 1500 Model l

H67UCC9PW5AN 700/800 MHz, 1-3, Watts ASTRO Analog MT 1500 Model I

ITEM NUMBER DESCRIPTION

X X 1585746D04 Cover, Dust, Accessory Connector

X X 4385665D01 Adapter, Remote Speaker Microphone

X X NTN9815_ Hi Capacity NiCd Battery

X X NAF5037_ 1/2 Wave Whip Antenna, 800 MHz

X X HLN6853_ 2.250 inch Belt Clip

X PMTN4080_ Front Cover Kit, XTS1500 Model I

X PMTN4079_ Front Cover Kit, MT1500 Model I

X X PMUF6541_ RF/VOCON Board Kit

X 6804113J52 User’s Guide, XTS1500 Model I

X 6804113J71 User’s Guide, MT1500 Model I

Specifications

xvi

Notes

1

Introduction 1

General This manual covers information needed for level one and two troubleshooting. Level one

troubleshooting consists of radio programming, tuning (via CPS/tuner), knobs

replacement, and installation and removal of antenna, belt clip, battery, and universal

connector cover. Level two troubleshooting consists of everything listed in level one, plus

the identification and replacement of Field Replaceable Units (FRUs). No soldering will be

allowed; only board swapping.

Included in this manual are radio specifications for the 700/800 MHz frequency bands, a

general description of ASTRO Digital XTS 2500 models, recommended test equipment,

service aids, radio alignment procedures, general maintenance recommendations, and

procedures for basic assembly and disassembly.

Notations Used in

This Manual Throughout the text in this publication, you will notice the use of warnings, cautions, and

notes. These notations are used to emphasize that safety hazards exist, and care must be

taken and observed.

NOTE: An operational procedure, practice, or condition, etc., which is

essential to emphasize.

CAUTION indicates a potentially hazardous situation which, if not

avoided, may result in equipment damage.

!

C a u t i o n

WARNING indicates a potentially hazardous situation which, if

not avoided, could result in death or injury.

!

W A R N I N G

!

DANGER indicates an imminently hazardous situation

which, if not avoided, will result in death or injury.

D A N G E R

!

Introduction

2

Radio

Description The ASTRO Digital XTS 2500 radios are among the most sophisticated two-way radios

available.

One of the newest in a long line of quality Motorola products, the ASTRO Digital XTS

2500 radio provides improved voice quality across more coverage area. The digital process,

called “embedded signalling,” intermixes system signalling information with digital voice,

resulting in improved system reliability, and the capability of supporting a multitude of

advanced features. Such features add up to better, more cost-effective two-way radio

communications.

ASTRO Digital XTS 2500 radios are available in three basic models. Table 1 describes

their basic features.

FLASHport The ASTRO® Digital XTS 2500 radio utilizes Motorola’s revolutionary FLASHport™

technology. FLASHport makes it possible to add software that drives the radio’s

capabilities both at the time of purchase and later on. Previously, changing a radio’s features

and capabilities meant significant modifications, or buying a new radio. But now, just as a

computer can be loaded with different software, the radio’s features and capabilities can be

upgraded with FLASHport software.

Table 1. ASTRO XTS 2500 Basic Features

Feature Model I Model II Model III

Display None LCD

6 lines/

12 characters per line

LCD

6 lines/

12 characters per line

Keypad None 3 x 2 button with

4-Position Navigation but-

ton

3 x 6 button with

4-Position Navigation but-

ton

Channel Capability 48 160 160

Dialing from Prestored List No Yes Yes

Programmable Softkeys No Yes Yes

3

Basic Maintenance 2

Introduction to

This Section This section of the manual describes preventive maintenance and handling precautions.

Each of these topics provides information vital to the successful operation and maintenance

of your radio.

Preventive

Maintenance ASTRO Digital XTS 2500 radios do not require a scheduled preventive maintenance

program; however, periodic visual inspection and cleaning is recommended.

Inspection Check that the external surfaces of the radio are clean, and that all external controls and

switches are functional. A detailed inspection of the interior electronic circuitry is not

needed.

Cleaning The following procedures describe the recommended cleaning agents and the methods to

be used when cleaning the external surfaces of the radio. External surfaces include the

housing assembly and battery case. These surfaces should be cleaned whenever a periodic

visual inspection reveals the presence of smudges, grease, and/or grime.

The only recommended agent for cleaning the external radio surfaces is a 0.5% solution of

a mild dishwashing detergent, such as JOY®, in water.

Cleaning External

Plastic Surfaces The detergent-water solution should be applied sparingly with a stiff, non-metallic, short-

bristled brush to work all loose dirt away from the radio. A soft, absorbent, lintless cloth or

tissue should be used to remove the solution and dry the radio. Make sure that no water

remains entrapped near the connectors, cracks, or crevices.

The effects of certain chemicals and their vapors can have harmful results

on certain plastics. Aerosol sprays, tuner cleaners, and other chemicals

should be avoided.

!

C a u t i o n

Basic Maintenance

4

Handling

Precautions Complementary metal-oxide semiconductor (CMOS) devices, and other high-technology

devices, are used in this family of radios. While these devices have many attributes, their

characteristics make them susceptible to damage by electrostatic discharge (ESD) or high-

voltage charges. Damage can be latent, resulting in failures occurring weeks or months

later. Therefore, special precautions must be taken to prevent device damage during

disassembly, troubleshooting, and repair. Handling precautions are mandatory for this

radio, and are especially important in low-humidity conditions.

Never heat the RF PA above 210°C while performing repair or rework procedures to

maintain its integrity. Utilizing a Chipmaster (R1319 or R1321) top-side set point of 215°C

and a Dragon (R1427) bottom-side pre-heat set point of 180°C has proven to satisfy this

condition during the rework of the RF PA (note: the RF PA temperature does not reach the

Chipmaster’s internal set point temperature). All other parts on the transceiver board can

be reworked with Chipmaster top-side heat alone.

5

Basic Theory of Operation 3

General

Overview The ASTRO Digital XTS 2500 radio is a wideband, synthesized, fixed-tuned radio

available in the 700/800 MHz bands. All XTS 2500 radios are capable of both analog

operation (12.5 kHz or 25 kHz bandwidths) and digital ASTRO mode operation (12.5 kHz

only).

The ASTRO Digital XTS 2500 radio includes the following major assemblies (see Figure

1):

•Main Board: contains the microcontrol unit (MCU) and its associated memory and

memory management integrated circuit (IC), the audio power amplifier, and a

switching regulator. The board also contains the digital signal processor (DSP) and its

support IC and associated memories. It further contains all transmit, receive, and

frequency generation circuitry, including the digital receiver back-end IC and the

reference oscillator.

•Universal Flex: contains the universal connector, speaker, and microphone.

•Display (Models II and III only): a six-line, 12-character, liquid-crystal display

(LCD).

•Keypad (Models II and III only):

-Model II: a 3 x 2 keypad

-Model III: a 3 x 6 keypad.

Figure 1. XTS 2500 Overall Block Diagram

Universal

Flex

(Side Connector,

Controls, LEDs,

Speaker,

Microphone)

Note:

indicates 20

wires

Main

Board

7.5V

Battery

Keypad

Antenna

Display

3

20

45

22

20

13

J601

J650 J101

B500

Basic Theory of Operation

6

Analog Mode of

Operation

Receiving When the radio is receiving (see Figure 2), the signal comes from the antenna connector to

the radio board, passes through the RX/TX antenna switch and into the receiver front end.

A 15dB step attenuator is included in the front end to provide additional protection against

strong signals. The attenuator is controlled by a DSP based algorithm that continuously

monitors signal strength. When the ON threshold is exceeded (approximately -95dBm), the

attenuator is activated via a DAC in the PCIC by the host. The attenuator remains activated

until the signal drops below the OFF threshold (approximately -115dBm including the

15dB attenuation). Hysterisis and timer functions are included in the algorithm to enhance

performance. The algorithm controlling the attenuator is enabled via the CPS for each

personality. When the algorithm is disabled, the attenuator is essentially a short circuit from

input to output.The signal is then filtered, amplified, and mixed with the first local-

oscillator signal generated by the voltage-controlled oscillator (VCO).

The resulting intermediate frequency (IF) signal is fed to the IF circuitry, where it is again

filtered and amplified. This amplified signal passes to the digital back-end IC, where it is

mixed with the second local oscillator to create the second IF at 450 kHz. It is then

converted to a digital bit stream and mixed a third time to produce a baseband signal. This

signal is passed to the VOCON circuitry through a current-driven differential output.

In the VOCON circuitry, the digital-signal processor (DSP) support IC digitally filters and

discriminates the signal, and passes it to the DSP. The DSP decodes the information in the

signal and identifies the appropriate destination for it. For a voice signal, the DSP routes

the digital voice data to the CODEC for conversion to an analog signal. The CODEC then

presents the signal to the audio power amplifier, which drives the speaker. For signalling

information, the DSP decodes the message and pass it to the microcontrol unit.

Transmitting When the radio is transmitting (see Figure 3), microphone audio is passed through gain

stages to the CODEC where the signal is digitized. The CODEC passes digital data to the

DSP where pre-emphasis and low-pass (splatter) filtering are done. The DSP passes this

signal to a digital-to-analog (D/A) converter where it is reconverted into an analog signal

and scaled for application to the voltage-controlled oscillator as a modulation signal.

Figure 2. Receiver Block Diagram

RF Input RX Front End

Harmonic

Filter

ADC

LO CKO

RX_SSI_ DATA

to VOCON Board

XTAL

Filter

ABACUS III - RX Back End

Antenna

Switch Tuneable

Preslector RF

Amp

Attenuator

Tuneable

Preselector

Filter 1st

Mixer

1st LO

3

MAEPF-27278-O

Basic Theory of Operation

7

Transmitted signalling information is accepted by the DSP from the microcontrol unit,

coded appropriately, and passed to the D/A converter, which handles it the same as a voice

signal. Modulation information is passed to the synthesizer along the modulation line. A

modulated carrier is provided to the RF PA, which transmits the signal under dynamic

power control.

ASTRO Mode of

Operation In the ASTRO mode (digital mode) of operation, the transmitted or received signal is

limited to a discrete set of deviation levels, instead of continuously varying. The receiver

handles an ASTRO-mode signal identically to an analog-mode signal up to the point where

the DSP decodes the received data. In the ASTRO receive mode, the DSP uses a

specifically defined algorithm to recover information.

In the ASTRO transmit mode, microphone audio is processed identically to an analog mode

with the exception of the algorithm the DSP uses to encode the information. This algorithm

will result in deviation levels that are limited to discrete levels.

RF Basic Theory

of Operation The receiver front end consists of a preselector, an RF amplifier, a second preselector, and

a mixer. Both preselectors are varactor-tuned, two-pole filters, controlled by the

microcontroller unit through the D/A IC. The RF amplifier is a dual-gate, gallium-arsenide-

based IC. The mixer is a double-balanced, active mixer, coupled by transformers. Injection

is provided by the VCO through an injection filter. See Table 2 for local oscillator (LO) and

first IF information.

The frequency generation function is performed by three ICs and associated circuitry. The

reference oscillator provides a frequency standard to the synthesizer/prescaler IC, which

controls the VCOB IC. The VCOB IC actually generates the first LO and transmit-injection

Figure 3. RF Block Diagram (Power and Control Omitted)

Reference

Oscillator

FracN

U201

MOD

IN

Loop

Filter

LPF

FL200

EPIC

Y200

DAC

U203

VCO

VCOBIC

U250

VCO

Crystal

Filter

FL3

Mixer

U1

2ND

LO

Sample

Clk

To RX_SSI

From TX_SSI

Preselector

Filter

FL2

Attenuator

PCIC

U102

Power

Module

Q101

TX

Buffer

Q216

TX Driver

Amplifier

U101

RF Power

Detector

D103

Directional

Coupler

U106

Antenna

Switch

Preselector

Filter

FL1

RX LNA

Q1

To

Antenna

Harmonic

Filter

ABACUS III U401

MAEPF-27322-O

VCO

3

3

Table 2. Local Oscillator and First IF Frequencies

700 MHz 800 MHz

LO Frequency Range -- --

First IF Frequency 109.65 MHz 109.65 MHz

Basic Theory of Operation

8

signals and buffers them to the required power level. The synthesizer/prescaler circuit

module incorporates frequency-division and comparison circuitry to keep the VCO signals

stable. The synthesizer/prescaler IC is controlled by the microcontrol unit through a serial

bus.

The receiver back end consists of a two-pole crystal filter, an IF amplifier, a second two-

pole crystal filter, and the digital back-end IC. The two-pole filters are wide enough to

accommodate 4 kHz modulation. Final IF filtering is done digitally in the DSP.

The digital back-end IC consists of an amplifier, the second mixer, an IF analog-to-digital

converter, a baseband down-converter, and a 2.4 MHz synthesis circuit to provide a clock

to the DSP-support IC on the VOCON circuitry. The second LO is generated by discrete

components external to the IC. The output of the digital back-end IC is a digital bit stream

that is current driven on a differential pair for a reduction in noise generation.

The transmitter consists of an RF driver IC that gets an injection signal from the VCO and

a final-stage power amplifier. Transmit power is controlled by a power-control IC that

monitors the output of a directional coupler and adjusts PA control voltages

correspondingly. The signal passes through a RX/TX switch that uses PIN diodes to

automatically provide an appropriate interface to transmit or receive signals. Antenna

selection is done mechanically in the control top.

VOCON Basic

Theory of

Operation

The vocoder and controller (VOCON) circuitry contains the radio’s microcontrol unit with

its memory and support circuits, the DSP, its memory devices, and the DSP-support IC,

voltage regulators, audio, and power control circuits. Connected to the VOCON circuitry

are the display board, RF circuitry, keypad board, and controls/universal flex.

The microcontrol unit controls receive/transmit frequencies, power levels, display, and

other radio functions, using either direct logic control or serial communications paths to the

devices.The microcontrol unit executes a stored program located in the FLASH ROM. Data

is transferred to and from memory by the microcontrol unit data bus. The memory location

from which data is read, or to which data is written, is selected by the address lines.

The DSP-support IC is supplied with a 16.8 MHz clock from the RF circuitry. Both the DSP

and the microprocessor have their clocks generated by the DSP-support IC. They can both

be adjusted so that the harmonics do not cause interference with the radio’s receive channel.

The regulator and power-control circuits include 3.3-volt analog, 3.3-volt digital, and 5-

volt regulators. The audio PA is sourced from 7.5V. The regulator’s power-down mode is

controlled by the microcontrol unit, which senses the position of the on/off switch. The 5-

volt regulator has an error pin for low-voltage resets.

The DSP performs signalling and voice encoding and decoding, as well as audio filtering

and volume control. This IC performs Private-Line®/Digital Private Line™ (PL/DPL)

encode and alert-tone generation. The IC transmits pre-emphasis on analog signals and

applies a low-pass (splatter) filter to all transmitted signals. It requires a clock on the

EXTAL pin. An 8 kHz interrupt signal generated by the DSP-support IC is also required

for functionality. It is programmed using parallel programming from the microcontrol unit.

The audio CODEC performs analog-to-digital (A/D), and digital-to-analog conversions on

audio signals. The DSP controls squelch, deviation, and executes receiver and transmitter

filtering. The DSP-support IC receives a 2.4 MHz clock, and also receives data, which it

formats for the DSP.

9

Recommended Test

Equipment and Service Aids 4

Recommended

Test Equipment The list of equipment contained in Table 3 includes all of the standard test equipment

required for servicing two-way portable radios, as well as several unique items designed

specifically for servicing this family of radios. The “Characteristics” column is included so

that equivalent equipment may be substituted; however, when no information is provided

in this column, the specific Motorola model listed is either a unique item or no substitution

is recommended.

Table 3. Recommended Test Equipment

Motorola

Model Number Description Characteristics Application

R2600 Series Communications

System Analyzer

This monitor will substitute for

items with an asterisk (*).

Frequency/deviation meter and signal

generator for wide-range

troubleshooting and alignment.

Fluke 8012 Digital Multimeter Recommended for ac/dc voltage and

current measurements

R1150_* Code Synthesizer Injection of audio and digital

signalling codes

R1377_* AC Voltmeter 1mV to 300V, 10-Megohm input

impedance

Audio voltage measurements

R1094_ Dual-Trace

Oscilloscope

20 MHz bandwidth 5mV to 5V/

division

Waveform measurements

S1350_*

ST1213_ (VHF)*

ST1223_ (UHF)*

Wattmeter

Plug-In Element

RF Dummy Load

50-ohm, ±5% accuracy

10 watts, maximum

0-1000 MHz, 300W

Transmitter power output

measurements

R1065_ Load Resistor 10-watt Broadband For use with wattmeter

S1339_ RF Millivolt Meter 100µV to 3V RF RF-level measurements

R1013_* SINAD Meter Receiver sensitivity measurements

S1347_ or S1348_

(programmable)

DC Power Supply 0-20Vdc, 0-5 Amps

current limited

Bench supply for 7.5Vdc

*The R2600 Series monitor will substitute for these items.

Recommended Test Equipment and Service Aids

10

Service Aids Refer to Table 4., “Service Aids,” for a listing and description of the service aids designed

specifically for servicing this family of radios. These kits and/or parts are available from

the Motorola Parts Division offices listed in the “Replacement Parts Ordering” section

located on the inside back cover of this manual. While all of these items are available from

Motorola, most are standard shop equipment items, and any equivalent item capable of the

same performance may be substituted for the item listed.

NOTE: The Radio Interface Box (RIB), Smart Radio Interface

Box (SRIB), and any cables that connect with those

boxes are incompatible with the XTS 2500 radio and

should NOT be used.

Field

Programming

Equipment

This family of radios can be aligned and programmed in the field. This requires specific

equipment and special instructions. Refer to the applicable “CPS On-line Help” for

complete field programming information.

Table 4. Service Aids

Motorola Part Number Description Application

6685666D01 Chassis Opener Tool Used to remove radio knobs and to separate chassis from Front

Cover.

RKN-4106_ RS232/Radio/Test Set Cable Connects radio to RLN4460 Test Box and to RS232 computer

connector (DB9).

0180305G54 Battery Eliminator Interconnects radio to power supply.

RLN-4460 Portable Test Set Enables connection to the universal connector.

Allows switching for radio testing.

RVN-4181_ Customer Programming

Software

Customer Programming Software (CPS)/Tuner on one CD-ROM.

58-80348B33 SMA to BNC Adaptor Adapts radio’s antenna port to BNC cabling of test equipment.

RKN4105 USB/Radio/Test Set Cable Connects radio to RLN4460 test box and to USB computer

connector.

8180384M37 Test Fixture Provides for troubleshooting the radio board when the back

casting is removed.

11

Performance Checks 5

Introduction to

This Section This section covers performance checks used to verify that the radio meets published

specifications. The recommended test equipment listed in the previous section approaches

the accuracy of the manufacturing equipment, with a few exceptions. Accuracy of the

equipment must be maintained in compliance with the manufacturer’s recommended

calibration schedule. Checks should be performed if radio performance degradation is

suspected.

Setup Supply voltage can be connected from the battery eliminator. The equipment required for

alignment procedures is connected as shown in the “Radio Alignment Test Setup” diagram

(Figure 4).

Figure 4. Radio Alignment Test Setup

BNC

COMPUTER

AUDIO GENERATOR

SINAD METER

AC VOLTMETER

TX

RX

30 dB PAD

30 dB PAD

RF GENERATOR

SYSTEM ANALYZER

OR COUNTER

WATTMETER

BATTERY

ELIMINATOR

0180305G54

TRANSMIT

RECEIVE

RADIO

PROGRAM/TEST CABLE

RKN4106

AUDIO IN

SET TO APPROX. 450mV FOR Tx

MEASURE 80mV FOR Tx

SMA-BNC

58-80348B33

TEST SET

RLN-4460

Performance Checks

12

Initial equipment control settings should be as indicated in the Table 5, and should hold for

all alignment procedures except as noted.

Display Radio

Test Mode

Entering Display

Radio Test Mode

1. Turn the radio on.

2. Within 10 seconds after “Self Test” is complete, press Side button 3 five times in

succession.

3. The radio will show a series of displays that will give information regarding various

version numbers and subscriber specific information. The displays are described in

Table 6.

NOTE: All displays are temporary and will disappear without

any user intervention. If information is longer than the

physical length of the radio’s display, the information

will wrap around to the next display. After the last

display, “RF TEST” will be displayed. For non-display

radios, refer to the CPS Radio Information Screen.

Table 5. Initial Equipment Control Settings

System Analyzer Test Set Power Supply

Monitor Mode: Pwr Mon Spkr Set: A Voltage: 7.5Vdc

RF Attn: –70dB Spkr/Load: Speaker DC On/Standby: Standby

AM, CW, FM: FM PTT: OFF (center) Volt Range: 10Vdc

O'scope Source: Mod

O'scope Horiz: 10mSec/Div

O'scope Vert: 2.5 kHz/Div

O'scope Trig: Auto

Monitor Image: Hi

Monitor BW: Nar

Monitor Squelch: Mid CW

Monitor Vol: 1/4 CW

Current: 2.5Amps

Table 6. Front-Panel Access Test-Mode Displays

Name of Display Description Appears

“SERVICE” The literal string indicates the radio has entered test

mode.

Always.

Host Software Version The version of host firmware. Always.

DSP Software Version The version of DSP firmware. Always.

Model Number The radio’s model number as programmed in the

codeplug.

Always.

Serial Number The radio’s serial number as programmed in the

codeplug.

Always.

ROM Size The memory capacity of the host FLASH part. Always.

FLASHcode The FLASH codes as programmed in the codeplug. Always.

Performance Checks

13

4a. Press Side Button 1 to stop the displays and put the radio into the Control Top and

Keypad test mode (display radio). The test mode menu “CH TEST” will be

displayed. Go to the “Control Top and Keypad Test Mode (Display Radio)” section

on page 14.

NOTE: Each press of Side Button 1 will toggle between “CH TEST” and

“RF TEST.”

OR

4b. Press the Top Programmable Button to stop the displays and put the radio into the

RF test mode (display radio). The test mode menu “1 CSQ.” will be displayed,

indicating test frequency 1, Carrier SQuelch mode. Go to “RF Test Mode (Display

Radio)” in the next section.

RF Test Mode

(Display Radio)

When the ASTRO Digital XTS 2500 radio is operating in its normal environment, the radio's

microcomputer controls the RF channel selection, transmitter key-up, and receiver muting,

according to the customer codeplug configuration. However, when the unit is on the bench for

testing, alignment, or repair, it must be removed from its normal environment via a special

routine, called TEST MODE or “air test.”

1. Each additional press of Side Button 3 will advance to the next test channel. (Refer

to Figure 7.)

2. Pressing Side Button 2 will scroll through and access test environments as shown in

Figure 8.

NOTE: Transmit into a load when keying a radio under test.

Table 7. Test Frequencies

Frequency 700/800 MHz RX 700/800 MHz TX

F1 764.0625 764.0125

F2 769.0625 769.0125

F3 775.9375 775.9875

F4 851.0625 794.0125

F5 860.0625 809.0125

F6 869.9375 823.9875

F7 851.0625 851.0125

F8 860.0625 860.0125

F9 869.9375 869.8875

Performance Checks

14

Control Top and

Keypad Test

Mode (Display

Radio)

This test mode is used to verify proper operation of all radio buttons and switches if a failure

is suspected.

1. Press and hold the Top Programmable Button; all segments on the display will light,

and the LED on the control top will illuminate a red color.

2. Release the Top Programmable Button; “3/0” appears, indicating that the Top

Programmable Button is in the open condition.

3. Press the Top Programmable Button again; “3/1” appears, indicating that the Top

Programmable Button is in the closed condition.

4. Rotate the Mode/Zone Selector Switch; “4/0” through “4/15” appears, indicating

that the selector switch is in mode/zone position 1 through 16.

5. Rotate the Three-Position Concentric Switch; “65/0” through “65/2” appear.

6. Cycle through the 16-Position Programmable Switch; “67/0,”

“67/1,” and “67/2” appear.

7. Rotate the Volume Control; “2/0” through “2/255” appear.

8. Press Side Button 1; “96/1” appears; release, “96/0” appears.

9. Press Side Button 2; “97/1”appears; release, “97/0” appears.

10. Press Side Button 3; “98/1”appears; release, “98/0” appears.

11. Press the PTT Switch; “1/1” appears; release, “1/0” appears.

12. Keypad Checks:

Model III Only—

-Press 0, “48/1” appears; release, “48/0” appears.

-Press 1, “49/1” appears; release, “49/0” appears.

-Press 2, “50/1” appears; release, “50/0” appears.

-Press 3, “51/1” appears; release, “51/0” appears.

-Press 4, “52/1” appears; release, “52/0” appears.

-Press 5, “53/1” appears; release, “53/0” appears.

-Press 6, “54/1” appears; release, “54/0” appears.

Table 8. Test Environments

No. of

Beeps Display Description Function

1 CSQ Carrier Squelch RX: unsquelch if carrier detected

TX: mic audio

3TPLTone

Private-Line RX: unsquelch if carrier and

tone (192.8 Hz) detected

TX: mic audio + tone (192.8 Hz)

11 AST ASTRO RX: none

TX: 1200Hz tone **

12 USQ Carrier

Unsquelch RX: unsquelch always

TX: mic audio

** All deviation values are based on deviation tuning of this mode.

Performance Checks

15

-Press 7, “55/1” appears; release, “55/0” appears.

-Press 8, “56/1” appears; release, “56/0” appears.

-Press 9, “57/1” appears; release, “57/0” appears.

-Press *, “58/1” appears; release, “58/0” appears.

-Press #, “59/1” appears; release, “59/0” appears.

All Display Models—

-Press V, “128/1” appears; release, “128/0” appears.

-Press h, “129/1” appears; release, “129/0” appears.

-Press U, “130/1” appears; release, “130/0” appears.

-Press the left-hand D key on the top row of keys, “131/1” appears; release, “131/

0” appears.

-Press the center E key, “132/1” appears; release, “132/0” appears.

-Press the right-hand F key, “133/1” appears; release, “133/0” appears.

-Press @ button, “134/1” appears; release, “134/0” appears.

-Press X (up arrow), “135/1 appears; release, “135/0” appears.

-Press Y (down arrow), “136/1” appears; release, “136/0” appears.

Non-Display

Radio Test Mode

Entering Non-

Display Radio Test

Mode

1. Turn the radio on.

2. Within 10 seconds after the top green LED turns off, press Side button 3 five times in

succession.

3a. Press Side Button 1 to put the radio into the Control Top and Keypad test mode (non-

display radio). Go to the “Control Top and Keypad Test Mode (Non-Display Radio)”

section on page 16.

NOTE: Each press of Side Button 1 will toggle between Control Top and

Keypad test mode (non-display radio) and RF test mode (non-

display radio).

OR

3b. Press the Top Programmable Button to stop the displays and put the radio into the

RF test mode (non-display radio). Go to “RF Test Mode (Non-Display Radio)” in the

next section.

RF Test Mode (Non-

Display Radio)

When the ASTRO Digital XTS 2500 radio is operating in its normal environment, the radio's

microcomputer controls the RF channel selection, transmitter key-up, and receiver muting

according to the customer codeplug configuration. However, when the unit is on the bench for

testing, alignment or repair, it must be removed from its normal environment via a special

routine, called TEST MODE or “air test.”

1. Each additional press of Side Button 3 will advance to the next test channel. (Refer to

Table 7 on page 13.) The channel number is represented by the number of beeps

Performance Checks

16

emitted by the radio after the button press (for example, five beeps indicates channel

5).

2. Pressing Side Button 2 will scroll through and access test environments as shown in

Table 8 on page 14. The test environment is represented by the number of beeps

emitted by the radio after the button press (for example, 11 beeps indicate AST).

NOTE: Transmit into a load when keying a radio under test.

Control Top and

Keypad Test

Mode (Non-

Display Radio)

This test mode is used to verify proper operation of all radio buttons and switches if a failure

is suspected.

1. Press and hold the Top Programmable Button; the LED on the control top lights

red, and the radio beeps.

2. Release the Top Programmable Button; the radio beeps again.

3. Press the Top Programmable Button again; the radio beeps, indicating that the Top

Programmable Button is in the closed condition.

4. Rotate the Three-Position Concentric Switch; the radio beeps in each switch

position.

5. Rotate the Mode/Zone Selector Switch; the radio beeps in each switch position.

6. Cycle through the 16-Position Programmable Switch; the radio beeps in each switch

position.

7. Rotate the Volume Control; the radio beeps at each new volume setting.

8. Press Side Button 1; the radio beeps.

9. Press Side Button 2; the radio beeps.

10. Press Side Button 3; the radio beeps.

Performance Checks

17

Table 9. Receiver Performance Checks

Test Name System Analyzer Radio Test Set Comments

Reference

Frequency Mode: PWR MON 4th channel

test frequency*

Monitor: Frequency error. Input

at RF In/Out

TEST MODE, 4

CSQ output at

antenna

PTT to continuous (during

the performance check)

Frequency error to be

≤ ±1.3 kHz

Rated Audio Mode: GEN

Output level: 1.0mV RF 4th

channel test frequency*

Mod: 1 kHz tone at 3 kHz

deviation

Monitor: DVM: ac Volts

TEST MODE, 4

CSQ

PTT to OFF (center);

meter selector to Audio PA

Set volume control to

3.74Vrms

Distortion As above, except to distortion As above As above Distortion < 3.0%

Sensitivity

(SINAD)

As above, except SINAD; lower

the RF level for 12dB SINAD

As above PTT to OFF (center) RF input to be <

0.35µV

Noise Squelch

Threshold (only

radios with

conventional

system need to be

tested)

RF level set to 1mV RF As above PTT to OFF (center);

meter selection to Audio

PA; spkr/load to speaker

Set volume control to

3.74Vrms

As above, except change

frequency to a conventional

system. Raise RF level from

zero until radio unsquelches.

Out of TEST

MODE; select a

conventional

system

As above Unsquelch to occur at

< 0.25µV. Preferred

SINAD = 5-8dB

*See Table 7 on page 13.

Performance Checks

18

Table 10. Transmitter Performance Checks

Test Name System Analyzer Radio Test Set Comments

Reference

Frequency Mode: PWR MON 4th

channel test frequency*

Monitor: Frequency error.

Input at RF In/Out

TEST MODE, 4

CSQ

PTT to continuous

(during the performance

check).

Frequency error to be ≤ ±1.3

kHz.

Power RF As above As above,

4 CSQ

As above Refer to Maintenance

Specifications page in front of

manual.

Voice

Modulation Mode: PWR MON 4th

channel test frequency*

atten to –70, input to RF In/

Out.

Monitor: DVM, ac Volts. Set

1 kHz Mod Out level for

0.025Vrms at test set,

80mVrms at ac/dc test set

jack

As above,

4 CSQ

As above, meter

selector to mic Deviation: ≥ 4.1 kHz but ≤

5.0 kHz

Voice

Modulation

(internal)

Mode: PWR MON 4th

channel test frequency*

atten to –70, input to RF In/

Out

TEST MODE, 4

CSQ, output at

antenna

Remove modulation

input

Press PTT switch on radio.

Say “four” loudly into the

radio mic. Measure

deviation: ≥ 4.1 kHz but ≤ 5.0

kHz

PL Modu-lation

(radios with

conven-tional,

clear mode,

coded squelch

oper-ation only)

Change frequency to a

conventional transmit

frequency

Conventional

coded squelch

personality

(clear mode

operation) 4

TPL

As above Deviation: ≥ 500Hz but ≤

1000Hz

Talkaround

Modulation

(radios with

conventional,

clear mode,

talk-around

operation only)

Change frequency to

conventional talk-around

frequency.

Mode: PWR MON

deviation, attenuation to –70,

input to RF In/Out.

Monitor: DVM, ac volts Set

1 kHz Mod Out level for

25mVrms at test set.

Conventional

talkaround

personality

(clear mode

operation)

1 CSQ

As above Deviation: ≥ 4.1 kHz but ≤

5.0 kHz

*See Table 7 on page 13

19

Radio Alignment

Procedures 6

Introduction to

This Section

This section describes both receiver and transmitter radio alignment procedures.

General A personal computer (PC) and tuner software are required to align the radio. Refer to the

applicable manual for installation and setup procedures for the software. To perform the

alignment procedures, the radio must be connected to the PC and to a universal test set as

shown in Figure 4. Radio Alignment Test Setup on page 11.

Select Tuner from the START menu. To read the radio, use the File ➝ Read Device menu

or click on . Figure 5 illustrates how the alignment screens are organized. To access a

screen, double-click on the desired screen name in the Tuner menu.

These procedures should only be attempted by qualified service

personnel. Failure to perform alignment procedures properly may result

in seriously degraded radio or system performance.

Figure 5. Tuner Menu Layout

!

C a u t i o n

123ABC1234

Radio Information

Transmitter Alignments

Reference Oscillator (page 21)

Tx Power High (page 23)

Tx Power Mid (page 23)

Tx Power Low (page 23)

Tx Deviation Balance (page 25)

Tx Deviation Limit (page 27)

Receiver Alignments

Front End Filter (page 28)

Performance Testing

Bit Error Rate (page 29)

Transmitter Test Pattern (page 31)

Radio Alignment Procedures

20

The alignment screens introduce the concept of the “softpot,” an analog SOFTware-

controlled POTentiometer used for adjusting all transceiver alignment controls.

Each alignment screen provides the ability to increase or decrease the softpot value by

using a slider or the screen’s UP/DOWN arrow keys (▲ ▼), or by entering the new value

from the keyboard. A graphical scale on the display indicates the minimum, maximum, and

proposed value of the softpot; see Figure 6.

Adjusting the softpot value sends information to the radio to increase (or decrease) a

voltage in the corresponding circuit. For example, left-clicking the UP arrow ▲ on the

Reference Oscillator screen instructs the radio’s microcomputer to increase the voltage

across a varactor in the reference oscillator, which increases the frequency.

In ALL cases, the softpot value is just a relative number corresponding to a digital-to-

analog (D/A) generated voltage in the radio.

Perform the following procedures in the sequence indicated.

NOTE: Some of the following screens may vary depending upon the radio under

test and the version of tuner software you are using. Refer to the

software’s on-line help.

Do NOT switch radios in the middle of any Alignment procedure.

Always left-click the Close button on the screen to return to the MAIN

menu screen before disconnecting the radio. Improper exits from the

Alignment screens may leave the radio in an improperly configured

state and result in seriously degraded radio or system performance.

Figure 6. Typical Softpot Screen

!

C a u t i o n

Radio Alignment Procedures

21

Radio Information Figure 7 shows a typical Radio Information screen.

Reference

Oscillator

Alignment

Adjustment of the reference oscillator is critical for proper radio operation. Improper

adjustment will result not only in poor operation, but also in a misaligned radio that will

interfere with other users operating on adjacent channels. For this reason, the reference

oscillator should be checked every time the radio is serviced, or once a year, whichever

comes first. The frequency counter used for this procedure must have a stability of 0.1 ppm

(or better).

NOTE: Reference oscillator alignment is required after replacing (or servicing)

the transceiver board.

This test can be done with either the R-2670 Communication Analyzer or the

8901_Modulation Analyzer.

• Initial setup using the R-2670 Communication Analyzer:

-RF Control: MONITOR

-B/W: WB

-Freq: CPS frequency under test

-Attenuation: 20dB

-Mon RF in: RF I/O

-Meter: RF Display

-Mode: STD

-Input Level: uV or W

-Display: Bar Graphs

-Squelch: Mid-range or adjust as necessary

•Initial setup using the 8901_ Series Modulation Analyzer:

Figure 7. Radio Information Screen

Radio Alignment Procedures

22

-Press the green Automatic Operation button on the analyzer.

-Press the FREQ key.

-Type 7.1 followed by SPCL button to set the 8901B_ modulation analyzer for

maximum accuracy.

To align the reference oscillator:

1. Select the Reference Oscillator alignment screen. See Figure 8.

2. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen

indicates whether the radio is transmitting.

3. Measure the transmit RF frequency with your service monitor.

4. Adjust the reference oscillator’s softpot value until the measured value is as close as

possible to the frequency shown on the screen. See Table 11.

5. Left-click the Program All button on the screen to dekey the radio and save the tuned

values.

6. Left-click the Close button on the screen to return to the Transmitter Alignments

menu.

Figure 8. Reference Oscillator Alignment Screen

Table 11. Reference Oscillator Alignment

Band Target

VHF ±100 Hz

UHF R1 (380-470 MHz) ±100 Hz

700 MHz/800 MHz ±100 Hz

Radio Alignment Procedures

23

Transmit Power

Alignment

This alignment procedure adjusts the transmit power of the radio and must be performed

for three different power levels (Low, Mid, High), at multiple frequencies for each power

level, to allow for proper alignment across the entire RF band. The RF band is divided into

frequency zones with a calibration point (value) in each zone.

NOTES:

•The same softpot attenuation value will result in DIFFERENT radio output

power levels at different frequencies.

•All power measurements are to be made at the antenna port.

•Transmit Power alignment is required after replacing (or servicing) the

transceiver board.

1. Select the TX Power alignment screen. The screen will indicate the transmit frequencies

to be used. See Figure 9.

2. Left-click the desired frequency field (starting with the highest frequency shown).

3. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen

indicates whether the radio is transmitting.

4. Measure the transmit power of the radio with a service monitor.

5. Adjust the softpot value until the required power, as shown in Table 12, is indicated

on the service monitor.

6. Repeat the above process for all frequencies and all power levels.

Table 12. Transmit Power Settings

Power Level Test Frequencies

700/800 MHz

Low (1 Watt) 1.2 - 1.4W

Mid (2 Watts) 2.5W - 2.7W

High (3 Watts) 3.2W - 3.4W

Radio Alignment Procedures

24

7. Left-click the Program All button on the screen to dekey the radio and save the tuned

values.

Left-click the Close button on the screen to return to the Transmitter Alignments menu.

Figure 9. Transmit Power Alignment Screen (Typical)

Radio Alignment Procedures

25

Transmit Deviation

Balance Alignment

This alignment procedure balances the modulation contributions of the low- and high-

frequency portions of a baseband signal. Proper alignment is critical to the operation of

signalling schemes that have very low frequency components (for example, DPL) and

could result in distorted waveforms if improperly adjusted.

This procedure needs to be performed at multiple frequencies to allow for proper alignment

across the entire RF band. The RF band is divided into frequency zones with a calibration

point (value) in each zone.

NOTE: This alignment is required after replacing (or servicing) the VOCON

board or the transceiver board.

Proper alignment requires a modulation analyzer or meter with a frequency response to less

than 10 Hz modulating frequency. The modulation analyzer settings during this test should

be set for average deviation, a 15 kHz low-pass filter, no de-emphasis, and no high-pass

filter, if these settings are supported.

This test can be done with either the R-2670 Communication Analyzer or the 8901_ Series

Modulation Analyzer. The method of choice is the R-2670 analyzer.

1. Initial setup using the R-2670 Communication Analyzer:

-Connect a BNC cable between the “DEMOD OUT” port and the “VERT/SINAD

DIST/DMM COUNTER IN” port on the R-2670.

-Press the SPF key on the R-2670 to display the “SPECIAL FUNCTIONS

MENU.” Move the cursor to “High Pass,” and select 5 Hz on the soft key menu.

Select 20 kHz for the “Low Pass” setting.

-In the “RF Control” section of the R-2670, enter the frequency displayed on the

RSS screen. Move the cursor to the “B/W” setting and select “WIDE +/- 100 kHz”

on the soft key menu.

-Place the R-2670 cursor in the “Display” zone. Select “AC VOLTS” on the soft

key menu. Move the cursor to the “Range” setting and select “AUTO.”

2. Initial setup using the 8901_ Series Modulation Analyzer:

-Press the FM MEASUREMENT button. (The “Error 03-input level too low”

indication is normal until an input signal is applied.)

-Simultaneously press the Peak – and Peak + buttons. Both LEDs on the buttons

should light.

-Press the 15 kHz LP filter key.

3. Select the TX Deviation Balance alignment screen. The screen indicates the transmit

frequencies to be used. See Figure 10.

4. Left-click the desired frequency field (starting with the highest frequency shown).

5. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen

indicates whether the radio is transmitting.

Radio Alignment Procedures

26

6. Left-click the PTT Tone: Low button.

7. Left-click the PTT Toggle button on the screen to enable transmission. The screen

indicates whether the radio is transmitting. Wait approximately 5 seconds until the

voltage shown on R-2670, or the deviation shown on the 8901_ analyzer, stabilizes.

8. Measure and record the ac voltage value from the R-2670 analyzer or the deviation

value from the 8901_ series analyzer.

9. Left-click the PTT Tone: High button.

10. Adjust the softpot value until the measured deviation/voltage, when using the high

tone, is within +/- 1.5% of the value observed when using the low tone.

11. Repeat the above process for all frequencies.

12. Left-click the Program All button on the screen to dekey the radio and save the tuned

values.

13. Left-click the Close button on the screen to return to the Transmitter Alignments

menu.

Figure 10. Transmit Deviation Balance Alignment Screen

Radio Alignment Procedures

27

Transmit

Deviation Limit

Alignment

This alignment procedure limits the modulation of a baseband signal. It is used for primary

modulation limiting.

This procedure needs to be performed at multiple frequencies to allow for proper alignment

across the entire RF band. The RF band is divided into frequency zones with a calibration

point (value) in each zone.

NOTE: This alignment is required after replacing (or servicing) the VOCON

board or the transceiver board.

1. Select the TX Deviation Limit alignment screen. The screen will indicate the

transmit frequencies to be used. See Figure 11.

2. Left-click the desired frequency field (starting with the highest frequency shown).

3. Left-click the PTT Toggle button on the screen to make the radio transmit. The screen

indicates whether the radio is transmitting.

4. Measure the transmitted signal deviation of the radio with a service monitor.

5. Adjust softpot value until the measured deviation is as close as possible to 2.83 kHz.

6. Repeat the above process for all frequencies.

7. Left-click the Program All button on the screen to dekey the radio and save the tuned

values.

Figure 11. Transmit Deviation Limit Alignment Screen

Radio Alignment Procedures

28

8. Left-click the Close button on the screen to return to the Transmitter Alignments

menu.

Front End Filter

Alignment

Definition This alignment procedure adjusts the front end receiver bandpass filters for best receiver sensitivity

and selectivity. It should be performed for all test frequencies to allow for proper software

interpolation for frequencies in between the test frequencies in the band (see Figure 12).

NOTE: Rx Front End Filter Alignment is required after replacing (or servicing)

the transceiver board.

Procedure for 700

MHz Frequencies

1. Left-click the desired frequency field.

2. Apply an RF signal with no modulation at -90 dBm on the current operating

frequency.

3. Start with a softpot value (approximately 10 or 20), increase softpot in ascending

order, and note the RSSI values. The RSSI will reach a peak value and remain stable

and then decrease. Allow the limits of the peak range to be defined as RSSI PEAK - 3.

Choose the middle of the peak range and program the corresponding softpot value as

the tuned softpot value.

4. Repeat the above process for all 700MHz frequencies.

5. Click on the “Program All” button to save the tuned values in the radio.

Procedure for 800

MHz Frequencies

1. Left-click the desired frequency field.

2. Apply an RF signal with no modulation at -90 dBm on the current operating

frequency.

3. Start with a softpot value of 50, increase softpot in ascending order, and note the RSSI

values. The RSSI will reach a peak value and remain stable and then decrease. Allow

the limits of the peak range to be defined as RSSI PEAK - 3. Note the upper end of

the peak range and program the corresponding softpot value as the tuned softpot

value.

4. Repeat the above process for all 800MHz frequencies.

5. Click on the “Program All” button to save the tuned values in the radio.

Procedure for UHF/

VHF

1. Left-click the desired frequency field.

2. Apply an RF signal with no modulation at -90 dBm on the current operating

frequency.

3. Adjust the softpot value until the maximum RSSI value is found.

4. Repeat the above process for all frequencies.

Refer to your Radio Service Manual for alignment procedure details.

This procedure should only be attempted by qualified service personnel.

!

C a u t i o n

Radio Alignment Procedures

29

Click on the “Program All” button to save the tuned values in the radio.

Bit Error Rate

Definition This screen is used to test the Bit Error Rate (BER) of the radio’s receiver at a desired

frequency.

Bit Error Rate Fields This screen contains the following fields:

Rx Frequency:

This field selects the Receive Frequency directly in MHz.

Test Pattern:

This field selects the Digital test pattern — TIA. Choices are: Standard Tone Test Pattern

(framed 1011) and Standard Interface Test Pattern (CCITT V.52).

Modulation Type:

Figure 12. Front End Filter Alignment Screen

Radio Alignment Procedures

30

This field represents the digital modulation type of the incoming signal on which BER is to

be calculated.

Continuous Operation:

This field allows the user to make the BER test repeat indefinitely. A selection of Yes will

cause the radio to calculate BER on a continuous basis and update the results on this screen

after each integration time. A selection of No will cause the BER test to execute for only

one sample of the integration time and then update the display.

Audio:

This field allows the user to select the audio output during a test. Selecting Internal will

cause the radio's built-in speaker to unmute to any signals at the desired frequency which

are present during the test. Selecting External will route the same signal to the radio's

accessory connector audio output. Selecting Mute will disable the audio output.

Integration Time:

This field represents the amount of time over which the Bit Error Rate is to be calculated.

The range is from 0.360 to 91.8 seconds in increments of 0.360 seconds.

NOTE: When Continuous Operation = Yes, all fields will be grayed out while

test is in progress. They will be enabled when the STOP button is

pressed.

When Continuous Operation = No, a wait cursor will be displayed while

the test is in progress and return to normal when the test is done.

Figure 13. Bit Error Rate Screen

Radio Alignment Procedures

31

Transmitter Test

Pattern

Definition This screen is used to transmit specific test patterns at a desired frequency so that the user

can perform tests on the radio’s transmitter.

Transmitter Test

Fields

This screen contains the following fields:

Tx Frequency:

This field selects the Transmit Frequency directly in MHz.

Channel Spacing:

This field allows the user to select the desired transmit deviation.

Test Pattern Type:

This field represents the type of test pattern which will be transmitted by the radio when

“PTT TOGGLE” button is pressed.

NOTE: Channel Spacing and Test Pattern Type fields will be grayed out while

radio is transmitting.

Figure 14. Transmitter Test Pattern Screen

Radio Alignment Procedures

32

Notes

33

XTS 2500/XTS 1500/MT 1500

Exploded View and Parts List 7

XTS 2500/XTS 1500/MT 1500 Model I Exploded View

12 31

7

10

4

11

3

1

9

21

19

18

MAEPF-27251-O

24

25

2

8

5

6

26

17

20

13

22

27

23

16

14

15

29

28

30

Table 13. Model I Exploded View Parts List

Item

Number Motorola Part

Number Description Item

Number Motorola Part

Number Description

1 1585746D01 Cover, Front Assembly Kit

(XTS2500)

26 2685785C01 Main Shield

1585746D04 Cover, Front Assembly Kit

(XTS1500/MT1500)

27 Typical Main Board

2 8485939D01 Assembly, Speaker/Microphone/

Universal Connector Flex

28 4385665D01 Adaptor, Remote Speaker Mic.

31385149D01 Bezel, PTT 29 Typical Battery

4 7585959C01 Keypad, PTT/Side Controls 30 Typical Belt Clip

54285446D01 Retainer, Speaker 31 0485667D01 Washer, Teflon

6 4285632D01 Retainer, Microphone Boot

73585469D01 Microphone Felt

8 1485218D01 Boot, Microphone

91385855C01 Label, ABC

10 3385466D01 Nameplate, Front (XTS2500)

3386597Z01 Nameplate, Front (XTS1500)

3386597Z02 Nameplate, Front (MT1500)

11 3385511D01 Label, Bottom

12 3585339D01 Speaker Mesh

13 0385563D01 Screw

14 1585405D01 Shroud

15 2785787C01 Chassis Cover, Rear

16 3285270D01 Seal, Main O-ring

17 4285633D01 Retaining Clip

18 3680529Z01 Knob, Volume

19 3685779C01 Knob, Frequency (W/D-Clip)

20 6003710K08 Battery, Backup

21 4585782C01 Lever, Concentric Switch

22 7585382D01 Pad, Thermal

23 3280534Z01 Seal, Contact

24 Typical Antenna

25 1505579Z01 Dust Cover, Universal Conn.

XTS 2500/XTS 1500/MT 1500 Exploded View and Parts List

34

XTS 2500 Model II Exploded View

18 5

13

39

16

4

17

9

8

7

2

6

14

3

11

10

12

19

28

22

21

20

36

1

29

15

27

25

24

MAEPF-27250-O

33

34

23

26

35

37

38

32

30

31

Table 14. Model II Exploded View Parts List

Item

Number Motorola Part

Number Description Item

Number Motorola Part

Number Description

1 1585746D02 Cover, Front Assembly Kit 30 Typical Antenna

20185947D01 Board, Model II 31 1505579Z01 Dust Cover, Universal Conn.

3 8485939D01 Assembly, Speaker/Microphone/

Universal Connector Flex

32 8485268D01 Board, Jumper Flex

41385149D01 Bezel, PTT 33 7585737D01 Spacer Pad

5 7585959C01 Keypad, PTT/Side Controls 34 2685785C01 Main Shield

67285726C01 Display Module 35 Typical Main Board

7 7585776C02 Keypad, Limited 36 4385665D01 Adaptor, Remote Speaker Mic.

87585915C01 Pad, Shock LCD 37 Typical Battery

9 4285214D01 Retainer, Keypad 38 Typical Belt Clip

10 4285446D01 Retainer, Speaker 39 0485667D01 Washer, Teflon

11 4285632D01 Retainer, Microphone Boot

12 4385717D01 Spacer, Plastic

13 3585469D01 Microphone Felt

14 1485218D01 Boot, Microphone

15 1385855C01 Label, ABC

16 3385466D01 Nameplate, Front

17 3385511D01 Label, Bottom

18 3585339D01 Speaker Mesh

19 0385563D01 Screw

20 1585405D01 Shroud

21 2785787C01 Chassis Cover, Rear

22 3285270D01 Seal, Main O-ring

23 4285633D01 Retaining Clip

24 3680529Z01 Knob, Volume

25 3685779C01 Knob, Frequency (W/D-Clip)

26 6003710K08 Battery, Backup

27 4585782C01 Lever, Concentric Switch

28 7585382D01 Pad, Thermal

29 3280534Z01 Seal, Contact

XTS 2500/XTS 1500/MT 1500 Exploded View and Parts List

35

XTS 2500 Model III Exploded View

18 5

13

16

4

17

9

8

7

2

6

14

3

11

10

12

19

28

22

21

20

36

1

29

15

27

25

24

MAEPF-27249-O

33

34

35

37

38

32

30

31 39

23

26

Table 15. Model III Exploded View Parts List

Item

Number Motorola Part

Number Description Item

Number Motorola Part

Number Description

1 1585746D03 Cover, Front Assembly Kit 30 Typical Antenna

20185948D01 Keypad Board, Model III 31 1505579Z01 Dust Cover, Universal Conn.

3 8485939D01 Assembly, Speaker/Microphone/

Universal Connector Flex

32 8485268D01 Board, Jumper Flex

41385149D01 Bezel, PTT 33 7585737D01 Spacer Pad

5 7585959C01 Keypad, PTT/Side Controls 34 2685785C01 Main Shield

67285726C01 Display Module 35 Typical Main Board

7 7585776C01 Keypad, Full 36 4385665D01 Adaptor, Remote Speaker Mic.

87585915C01 Pad, Shock LCD 37 Typical Battery

9 4285214D01 Retainer, Keypad 38 Typical Belt Clip

10 4285446D01 Retainer, Speaker 39 0485667D01 Washer, Teflon

11 4285632D01 Retainer, Microphone Boot

12 4385717D01 Spacer, Plastic

13 3585469D01 Microphone Felt

14 1485218D01 Boot, Microphone

15 1385855C01 Label, ABC

16 3385466D01 Nameplate, Front

17 3385511D01 Label, Bottom

18 3585339D01 Speaker Mesh

19 0385563D01 Screw

20 1585405D01 Shroud

21 2785787C01 Chassis Cover, Rear

22 3285270D01 Seal, Main O-ring

23 4285633D01 Retaining Clip

24 3680529Z01 Knob, Volume

25 3685779C01 Knob, Frequency (W/D-Clip)

26 6003710K08 Battery, Backup

27 4585782C01 Lever, Concentric Switch

28 7585382D01 Pad, Thermal

29 3280534Z01 Seal, Contact

XTS 2500/XTS 1500/MT 1500 Exploded View and Parts List

36

37

Disassembly/Assembly 8

Introduction to

This Section

This section contains basic procedures for removing and installing the following

components of the XTS 2500 radio:

•Antenna

•Battery

•Belt Clip

•Universal Connector Cover

•Remote Speaker Microphone Adapter

•Radio Disassembly—Detailed

•Radio Reassembly—Detailed

Antenna

Attach the Antenna With the radio off, turn the antenna clockwise to attach it.

Remove the

Antenna

With the radio off, turn the antenna counter-clockwise to remove it.

Figure 15. Attaching the Antenna

Figure 16. Removing the Antenna

Disassembly/Assembly

38

Battery

Attach the Battery 1. With the radio off, fit the three extensions at the bottom of the battery into the bottom

slots on the radio.

2. Press the top of the battery against the radio until both latches click into place.

Remove the Battery 1. With the radio off, slide down the latches on the sides of the battery.

2. Pull the top of the battery away from the radio.

Figure 17. Step 1, Attaching the Battery

Figure 18. Step 2, Attaching the Battery

Figure 19. Step 1, Removing the Battery

Figure 20. Step 2, Removing the Battery

Disassembly/Assembly

39

Belt Clip

Attach the Belt Clip 1. Align the grooves of the belt clip with those of the battery.

2. Press the belt clip downward until you clear a “click.”

Remove the Belt

Clip

1. Use a flat-bladed object to press the belt clip tab away from the battery.

2. Slide the belt clip upward to remove it.

Figure 21. Attaching the Belt Clip

Figure 22. Removing the Belt Clip

Disassembly/Assembly

40

Universal

Connector Cover

The universal connector cover is located on the antenna side of the radio. It is used to cover

the connector when not in use.

NOTE: To prevent damage to the connector, shield it with the

connector cover when not in use.

Remove the

Universal Connector

Cover

1. Insert a flat-blade screwdriver into the area between the bottom of the cover and the

slot below the connector.

2. Hold the top of the cover with your thumb while you pry the bottom of the cover

away from the radio with the screwdriver.

Attach the Universal

Connector Cover

1. Insert the, hooked end of the cover into the top of the connector.

2. Press downward on the top of the cover to seat it into the slot.

3. Press the lower tab of the cover below the connector until it snaps in place.

Figure 23. Removing the Universal Connector Cover

Figure 24. Attaching the Universal Connector Cover

Top

Slot

Bottom

Slot

Top

Hooked End

Bottom

Hooked End

Tab

Disassembly/Assembly

41

Remote Speaker

Microphone

Adapter

The Remote Speaker Microphone (RSM) adapter is located on the back of the radio, just

above the battery. It must be used to connect the RSM to the radio. If the RSM is not

used, the adapter must be removed.

Remove the Adapter Lift the larger side (below the antenna port) of the adapter away from the radio using your

finger.

If you cannot easily remove the adapter with your finger, use a small, flat bladed

screwdriver to pry the larger end side of the adapter away from the radio.

Attach the Adapter 1. With the Motorola side of the adapter facing out, snap the smaller end of the adapter

into place in the shroud indent, below the On/Off Volume Control Knob.

2. Snap the larger end of the adapter into place in the shroud indent, below the antenna

port.

Figure 25. Removing the RSM Adapter

Figure 26. Step 1, Attaching the RSM Adapter

Figure 27. Step 2, Attaching the RSM Adapter

Disassembly/Assembly

42

Radio

Disassembly—

Detailed

When disassembling and reassembling the radio, pay particular attention to the snaps and

tabs and how parts align with each other.

The following steps describe how to disassemble the radio. This includes the following

major components:

•Front Cover

•Chassis

•Backup Battery

•Keypad

•Keypad/option board

•Display

•Speaker, microphone, universal flex connector

•PTT

Required Tools •Small, flat-bladed screwdriver

•TORX™ T7-IP screwdriver

•Chassis Opener/Knob removal tool (Motorola part number 6685666D01)

Front Cover from

Chassis

Disassembly

For this section, please refer to the Model III exploded view and parts list on page 35 for

part numbers and more information on the location of parts in the radio.

1. Turn off the radio.

2. Remove the battery completely from the radio (see Figure 19 and Figure 20 on page

38).

3. Remove the antenna (see Figure 16 on page 37).

Table 16. Front Cover from Chassis Disassembly

Exploded

View

Item

Number

Motorola Part Number Description

1 1585746D03 Cover, Front Assembly Kit

3 8485939D01 Assembly Speaker/Microphone/Universal

Connector Flex

21 2785787C01 Chassis Cover, Rear

24 3680529Z01 Knob, Volume

25 3685779C01 Knob, Frequency (16-Position Select)

27 4585782C01 Lever, Concentric Switch

30 Typical Antenna

32 8485268D01 Board, Jumper Flex

37 Typical Battery

39 0485667D01 Washer, Teflon

Disassembly/Assembly

43

4. Pull the 16-Position Select and the On/Off/Volume Control knobs off their shafts

using the Chassis Opener tool.

5. After you remove the On/Off/Volume Control knob, remove the Teflon® washer

and set it aside.

6. Separate the chassis from the front cover by inserting the chassis opener between the

thin, plastic retaining wall and the metal chassis at the bottom of the radio.

Figure 28. Knob Removal

Be careful not to mar the O-ring sealing area on the housing. Marring

the front cover O-ring sealing areas will prevent the radio from

sealing properly.

Figure 29. Chassis Removal

!

W A R N I N G

!

KNOBS OPENER

CHASSIS OPENER

Disassembly/Assembly

44

7. Slowly pry the bottom of the chassis away from the front cover by pushing the chassis

opener tool down. Rotate the handle of the tool over and behind the base of the radio.

This prying action forces the thin inner plastic wall toward the base of the radio,

releasing the two chassis tabs.

8. Remove the chassis assembly by holding the chassis in one hand while slowly, with a

firm side-to-side motion, removing the chassis.

9. Lay the chassis down. Rotate the front cover backward and slightly away from the

chassis.

The chassis assembly has switches that can be damaged if the chassis

is removed too quickly. Be careful not to damage the switches at the

top of the board.

Figure 30. Chassis Separation

Flexible ribbon circuits (flexes) connecting the front cover assembly

and the chassis prevent you from completely separating the two units.

Display radios and radios with option boards have two flexes.

Figure 31. Unlatching the Flex Connectors

!

C a u t i o n

!

C a u t i o n

Disassembly/Assembly

45

10. Carefully lift the latches on the main circuit board to release the flexible circuits from

their connectors.

NOTE: For proper reassembly, note how the flex circuits are

folded.

11. Remove the concentric lever from the front cover assembly.

Chassis

Disassembly

For this section, please refer to the Model III exploded view and parts list on page 35 for

part numbers and more information on the location of parts in the radio.

1. If disassembly of the chassis or the main board is required, then use a TORX™

screwdriver with a T7-IP head to remove the five screws holding the main board and

shield to the chassis.

2. Remove the O-ring from around the bushing at the antenna connector

3. Lift the main board from the chassis as shown in Figure 32.

Table 17. Chassis Disassembly

Exploded

View

Item

Number

Motorola Part Number Description

19 0385563D01 Screw (5 required)

21 2785787C01 Chassis Cover, Rear

22 3285270D01 Seal, Main O-ring

34 2685785C01 Main Shield

35 Typical Main Board

Refer to the Handling Precautions on page 4 before removing the

main board. Be sure to use ESD protection when handing circuit

boards.

!

C a u t i o n

Disassembly/Assembly

46

4. Most repairs to the main board can be performed without further disassembly of the

chassis. If it is necessary to replace the O-ring, remove the small O-ring retainers

from their slots in the chassis. Note the alignment of the retainers for reassembly.

5. Remove the O-ring.

Backup Battery

Disassembly

For this section, please refer to the Model III exploded view and parts list on page 35 for

part numbers and more information on the location of parts in the radio.

1. The backup battery can be removed without disassembling the board or the chassis.

2. Remove the backup battery retaining clip by sliding it away from the main circuit

board, as shown in Figure 33.

3. Insert a small, flat head screwdriver between the battery and the battery holder.

Gently pry the battery out of the battery holder.

Figure 32. Removing the Main Board from the Chassis

Table 18. Backup Battery Disassembly

Exploded

View

Item

Number

Motorola Part Number Description

23 4285633D01 Retaining Clip

26 6003710K08 Battery, Backup

Disassembly/Assembly

47

Keypad and

Keypad/Option

Board Disassembly

For this section, please refer to the Model III exploded view and parts list on page 35 for

part numbers and more information on the location of parts in the radio. (For the Model II

keypad, please refer to the exploded view and parts list on page 34.)

1. The keypad and keypad board can be disassembled without the disassembly of the

display or speaker/microphone flex assembly.

2. If the disassembly of the keypad or the keypad printed circuit board is required, lift

the microphone flex circuit up to move it out of the way.

3. Disconnect the display connector, and move the tail of flex circuit out of the way.

4. To remove the keypad retainer shield, insert the tip of a “penknife size,” flat-bladed

screwdriver in the opening at the end of the keypad retainer arm tab. Pry the tab away

from the side of the front cover until it moves past the ledges on the side wall. Repeat

this procedure for the four remaining retainer arm tabs.

Figure 33. Remove the Backup Battery

Table 19. Keypad and Keypad/Option Board

Exploded

View Item

Number Motorola Part Number Description

2 0185948D01 Keypad Board, Model III

3 8485939D01 Assembly Speaker/Microphone/Universal

Connector Flex

6 7285726C01 Display Module

7 7585776C01 Keypad, Full (for Model III only)

9 4285214D01 Retainer, Keypad

22 3285270D01 Seal, Main O-ring

Be careful not to mar the O-ring sealing area on the housing. Marring

the front cover O-ring sealing areas will prevent the radio from

sealing properly.

!

W A R N I N G

!

Disassembly/Assembly

48

5. Lift the keypad retainer out of the front cover.

6. The keypad/option board and the keypad can be removed without the use of tools.

Figure 34. Retainer Removal

Figure 35. Keypad Retainer and Boards Removal

Disassembly/Assembly

49

Display

Disassembly

For this section, please refer to the Model III exploded view and parts list on page 35 for

part numbers and more information on the location of parts in the radio. (For the Model II

display, please refer to the exploded view and parts list on page 34.)

1. The display assembly can be removed without the disassembly of the keypad board or

the speaker-microphone flex assembly. If the disassembly involves the removal of the

display module, disconnect the display flex from the keypad option board connector.

2. The display module snaps into the front cover assembly. Insert two flat-bladed

screwdrivers between the flexible beam at the top of the display module (one on each

side). Deflect the beam down until it moves past the hooks on the front cover. The

display module is hooked to the front cover at the base of the display. Lift the top of

the display module past the hooks and remove it from the front cover.

Table 20. Display Disassembly

Exploded

View Item

Number Motorola Part Number Description

1 1585746D03 Cover, Front Assembly Kit (Model III)

2 0185948D01 Keypad Board, Model III

6 7285726C01 Display Module

9 4285214D01 Retainer, Keypad

Take care not to damage the display. Do not cut, bend, or pinch the heat

seal. Display modules contain CMOS devices. Be sure to use ESD

protection.

Figure 36. Display Disassembly

!

C a u t i o n

Disassembly/Assembly

50

Speaker,

Microphone, and

Universal Connector

Flex Disassembly

For this section, please refer to the Model III exploded view and parts list on page 35 for

part numbers and more information on the location of parts in the radio.

1. The speaker-microphone assembly can be removed without the disassembly of the

display or the keypad assemblies. If disassembly of the speaker-microphone assembly

is necessary, removal of the universal connector dust cover is optional (see Figure 23

on page 40).

2. Remove the plastic spacer at the bottom of the speaker. The spacer can be removed by

pulling upward with a slight, side-to-side motion until it clears the retaining ribs in the

front cover. Take special care to prevent damage to the tail of the speaker flex circuit

while the flex is still in place.

3. Using a screwdriver, push down on the portion of the speaker retainer bracket that is

pointing toward the bottom of the radio. Then, remove the retainer by slightly pushing

it toward the top of the radio until you slide it past the front cover slot.

4. Remove the microphone boot retainer by inserting a penknife-sized screwdriver in the

notch between the retainer and the housing. Pry the retainer away from the housing

and remove the clip.

5. Remove the microphone rubber boot by sliding it out of the pocket in the front cover.

Take care not to pull on the flex cable while pulling on the microphone boot. Unless

you are replacing the microphone, leave it in the boot. At this point, the speaker and

microphone are disconnected, but the assembly is still attached to the universal

connector by 13 pins in the printed circuit backer board.

6. To remove the speaker-microphone flex circuit from the universal connector,

carefully grasp the flex circuit at a point directly across from the universal connector

pins. Applying firm pressure, gradually pull the flex away from the pins.

Table 21. Speaker, Microphone, and Universal connector Flex Disassembly

Exploded

View Item

Number Motorola Part Number Description

1 1585746D03 Cover, Front Assembly Kit

3 8485939D01 Assembly Speaker/Microphone/Universal

Connector Flex

10 4285446D01 Retainer, Speaker

11 4285632D01 Retainer, Microphone Boot

12 4385717D01 Spacer, Plastic

14 1485218D01 Boot, Microphone

Disassembly/Assembly

51

NOTE: There are notches on the ends of the 13-pin printed

circuit backer board. If necessary, you can insert a small

screwdriver in one of the notches to pry the backer board

away from the front cover.

After the universal connector portion of the speaker-microphone flex circuit is

detached, the assembly can be completely removed. If it is necessary to replace the

speaker or the microphone, or both, do it while the flex circuit is removed from the

front cover.

PTT Disassembly For this section, please refer to the Model III exploded view and parts list on page 35 for

part numbers and more information on the location of parts in the radio.

1. If required, the PTT bezel and the PTT seal assembly can be disassembled using a

small screwdriver.

2. Remove the PTT bezel by pushing the snaps out at the top and pulling the bezel up

toward the top of the front cover so that the T-tab slides up and out.

3. The PTT seal can be easily lifted from the bezel without the use of tools.

Figure 37. Speaker-Microphone Removal

Table 22. PTT Disassembly

Exploded

View

Item

Number

Motorola

Part Number Description

1 1585746D03 Cover, Front Assembly Kit

4 1385149D01 Bezel, PTT

5 7585959C01 Keypad, PTT/Side Controls

Disassembly/Assembly

52

Radio

Reassembly—

Detailed

The following steps describe how to reassemble the radio. This includes the following

major components:

•PTT

•Keypad/option board

•Display

•Speaker, microphone, universal connector flex

•Chassis

•Backup Battery

•Chassis and front cover

PTT Reassembly 1. Put the PTT seal in the PTT bezel.

2. Align the PTT bezel and seal to the front cover housing so that the bottom tabs will

engage with the opening in the front cover.

3. Slide the PTT bezel down so that the T-tab engages into the front cover opening.

4. Snap the top snaps.

NOTE: Look inside the front cover to be sure the T-tab and snaps

are fully engaged with the front cover.

Figure 38. PTT Removal

Disassembly/Assembly

53

Keypad and Keypad

Option Board

Reassembly

1. Insert the keypad into the front cover. Align the keypad to the pins in the front cover.

2. Replace the board on the locator pins.

3. Replace the keypad retainer legs on the PTT side first. Then, press the retainer down

and snap the other two legs into place on the universal connector side; make sure that

all four legs snap into place. If necessary, use a small, flat-bladed screwdriver to put

pressure on the corner bend of each retainer leg.

Display Reassembly 1. Slide the two bottom tabs of the display module, with the LCD facing the front

housing lens, into the grooves located above the keypad assembly area in the front

cover housing. Gently press on the upper portion of the display until it snaps into

place past the two small hooks in the housing.

2. Connect the display flex to the keypad option board connector.

Speaker,

Microphone, and

Universal Connector

Flex Reassembly

1. Insert the microphone boot into the pocket in the front cover housing.

2. Insert the microphone boot plastic retainer. Make sure the retainer is securely hooked

to the front cover.

3. Center the speaker in the speaker recess. Make certain the speaker is correctly nested

inside the front cover.

4. Before you replace the speaker retainer, be sure the retainer is placed between the

speaker-microphone flex circuit and the speaker. Insert the flat end of the speaker

retainer into the opening in the front cover. Press the other end of the retainer against

the speaker. Hold the retainer in place with your thumb while pushing down on the

retainer with a flat-bladed screwdriver. Use the screwdriver to push down on the

portion of the speaker retainer that is pointing toward the bottom of the radio. Move

the retainer by pushing it toward the bottom of the radio. Slide it into the front cover

slot above the display.

5. Connect the universal flex to the pins and press into place.

Figure 39. Lock Retainer Catches to Radio Body

Disassembly/Assembly

54

Chassis Assembly

Reassembly

Before you assemble the main board to the chassis, make sure that the following steps are

done to the chassis.

1. Replace the O-ring. The tabs on the O-ring should reach into the chassis and point

down.

2. Stretch the O-ring to place it into the retaining pocket at the bottom end of the chassis.

NOTE: When properly assembled, the retainers on the O-ring

should align with the slots on the chassis. If this is not the

case, remove and replace the O-ring until it is aligned

with the chassis and completely seated in place around

the perimeter.

3. Replace the battery contact seal (if necessary) surrounding the battery contact.

NOTE: Be sure the battery contact seal protrudes through the

chassis and is not pinched under the chassis.

4. Make sure the thermal pad is placed on top of the RF Power Amplifier on the main

board.

5. Use the notch in the bottom of the main board and the protrusion at the bottom of the

casting to align the board to the casting. Place the board against the casting. Make

sure that the five screw holes are aligned.

6. Place the main shield assembly on the main board. Again, make sure that the five

screw holes are aligned.

7. Use the TORX T7-IP screwdriver to fasten the screws holding the main board and

shield to the chassis. Do not over torque. Torque limit is 4 inch-lbs.

8. Place the O-ring at the antenna connector over the antenna connector bushing.

Backup Battery

Reassembly

1. Insert the backup battery (positive side up) into the battery holder, as shown in Figure

40.

2. Replace the retaining clip by sliding it into its recess on the board.

Chassis and Front

Cover Reassembly

1. Align the chassis assembly end-to-end with the front cover assembly.

2. Insert the tails of the flex circuits into their respective connectors at the bottom of the

Figure 40. Reassemble the Backup Battery

Disassembly/Assembly

55

chassis assembly.

3. Push down the latches on the connectors to hold the flex circuits to the main board.

NOTE: Be sure the concentric lever is not in place on the

frequency knob shaft when reassembling the chassis with

the front cover assembly.

4. Align the volume knob shaft and the frequency switch shaft with their respective

holes in the front cover. Slowly reassemble the chassis and front cover assemblies.

Slowly slide the volume knob and frequency switch shafts into their respective holes

in the front cover.

NOTE: Make sure the flex circuits are correctly folded in place.

Take special care to prevent pinching or excess binding

of these flexes.

5. Push the chassis assembly completely into the top of the front cover until it settles in

place.

NOTE: Be sure the O-ring is properly seated.

6. Press down at the bottom of the chassis until the chassis snaps into place in the front

cover.

7. Reassemble the concentric lever to the frequency knob shaft by aligning the

protrusions in the lever with the openings in the shaft. The triangular-shaped side of

the lever should point toward the back of the radio.

8. Reassemble the Teflon washer to the volume knob shaft. Reassemble the knobs, dust

cover, antenna, and battery.

Figure 41. Fastening the Chassis

Disassembly/Assembly

56

Notes

57

Radio-Level Troubleshooting 9

Introduction to

This Section

This section of the manual contains troubleshooting charts and error codes that will help

you to isolate problems. Level one troubleshooting will support only radio alignment,

programming, battery replacement, and knob replacement. If the radio needs further

troubleshooting, it must be sent to the depot.

Board-level, component-level, and service information can be found in the ASTRO Digital

XTS 2500 Portable Radios Detailed Service Manual, Motorola publication number

68P81094C10.

Power-Up Error

Codes

When the radio is turned on (power-up), the radio performs cursory tests to determine if its

basic electronics and software are in working order. Problems detected during these tests

are presented as error codes on the radio’s display. For non-display radios, the problem is

indicated at power-up by a single, low-frequency tone. If cycling power and code plug

reprogramming do not fix the error, the radio should be sent to the depot for repair. The

presence of an error should prompt the user that a problem exists and that a service

technician should be contacted.

Self-test errors are classified as either fatal or non-fatal. Fatal errors will inhibit user

operation; non-fatal errors will not. Table 23. lists their descriptions and suggested

corrective action.

Radio-Level Troubleshooting

58

Operational Error

Codes

During radio operation, the radio performs dynamic tests to determine if the radio is

working properly. Problems detected during these tests are presented as error codes on the

radio’s display. Ann error code indicates that a problem exists and that a service technician

should be contacted. Operational error codes are listed in Table 24..

Table 23. Power-Up Error Code Displays

Error

Code Description Corrective Action

01/02 FLASH ROM Codeplug Checksum Non-Fatal Error Reprogram the codeplug.

01/12 Security partition Checksum Non-Fatal Error Send Radio to Depot.

01/22 Tuning Codeplug Checksum Non-Fatal Error Send Radio to Depot.

01/81 Host ROM Checksum Fatal Error Send Radio to Depot.

01/82 FLASH ROM Codeplug Checksum Fatal Error Reprogram the codeplug.

01/88 External RAM FATAL Error -- Note: not a checksum failure Send radio to depot.

01/90 General Hardware Failure Fatal Error Turn the radio off, then on.

01/92 Security Partition Checksum Fatal Error Send radio to depot.

01/93 Flashport AUTHENTIFICATION CODE failure Send radio to depot.

01/98 Internal RAM Fail Fatal Error Send radio to depot.

01/A0 ABACUS Tune failure Fatal Error Turn the radio off, then on.

01/A2 Tuning Codeplug Checksum Fatal Error Send radio to depot.

02/10 DSP Support IC Checksum Non-Fatal Error Turn the radio off, then on.

02/81 DSP ROM Checksum Fatal Error Send radio to depot.

02/88 DSP RAM Fatal Error -- Note: not a checksum failure Turn the radio off, then on.

02/90 General DSP Hardware Failure (DSP startup message not received

correctly)

Turn the radio off, then on.

NOTE: If the corrective action does not fix the failure, send the radio to the depot.

Table 24. Operational Error Code Displays

Error Code Description Corrective Action

FAIL 001 Synthesizer Out-of-Lock a. Reprogram external codeplug

b. Send radio to depot

FAIL 002 Selected Mode/Zone Codeplug Checksum Error Reprogram external codeplug

Radio-Level Troubleshooting

59

Table 25. Receiver Troubleshooting Chart

Symptom Possible Cause Correction or Test (Measurements

Taken at Room Temperature)

Radio dead; Display does not

light up

1. Dead Battery Replace with charged battery.

2. Blown Fuse Send radio to depot.

3. On/Off Switch

4. Regulators

Radio dead; display

lights up

1. VOCON Send radio to depot.

2. RF

No receiver audio or receiver

does not unmeet

Programming a. Does the transmitted signal match the receiver

configuration (PL, DPL, etc.)?

b. With the monitor function enabled, can the radio

be unmuted?

Audio distorted or not loud

enough

Synthesizer Not On

Frequency

Check synthesizer frequency by measuring the transmitter

frequency; if off by more than ±1000Hz, realign.

RF sensitivity poor 1. Synthesizer Not

On Frequency

Check synthesizer frequency by measuring the transmitter

frequency; if off by more than ≤ ±1000Hz, realign.

2. Antenna Switch Send radio to depot.

3. Receiver Front-

End Tuning

Check RF front-end tuning for optimum sensitivity using the CPS.

Radio will not turn off VOCON Send radio to depot.

Table 26. Transmitter Troubleshooting Chart

Symptom Possible Cause Correction or Test (Measurements Taken

at Room Temperature)

No RF power out 1. TX Power Level or Frequency Check TX power level and frequency

programming (from CPS).

2. No PTT From Control Top Send radio to depot.

3. No Injection To Power Amplifier

No modulation;

Distorted modulation

1. Programming Check deviation and compensation settings

using the CPS.

2. VOCON Send radio to depot.

Bad microphone sensitivity 1. Check Deviation and Compensation Realign if necessary.

2. Microphone Send radio to depot.

No/Low signalling

(PL, DPL, MDC)

1. Programming Check programming.

2. VOCON Send radio to depot.

Cannot set deviation balance RF Send radio to depot.

Radio-Level Troubleshooting

60

Notes

61

Accessories 10

General Motorola provides the following approved accessories to improve the productivity of your

XTS 2500 portable two-way radio.

Antennas

Audio

Headsets

Earpieces

Remote Speaker

Microphones

NAF5037 806-870 MHz Whip, Half-wave, 7 inch

NAF5042 806-870 MHz Quarter Wave, 3 inch, Stubby

NAF5080 764-870 MHz Whip, Half-wave, 6.5 inch

BDN6635 Boom Mic Headset with VOX (Adapter BDN6673)

BDN6636 Throat Mic Headset with VOX (Adapter BDN6673)

BDN6645 Noise-Canceling Boom Mic Headset with PTT on earcup

BDN6673 Headset Adapter Cable for use with BDN6645, BDN6635, and

BDN6636

NMN6258 Over the Head Headset w/ In Line PTT

NMN6259 Medium Weight Dual Headset with NC Mic

RMN4049 Temple Transducer

BDN6677 Ear mic, standard, noise up to 95dB, black (must order

Interface module)

BDN6641 Ear mic, high noise level up to 105dB, grey (must order

interface module)

NMN6193 Remote Speaker Microphone

NMN6191 RSM Noise Cancelling Includes: 6.0' coiled cord assembly,

3.5mm earjack, swivel clip, quick disconnect

Accessories

62

Surveillance

Batteries

Belt Clips

Carrying Cases

BDN6671 PTT and VOX Interface Module for use with BDN6677,

BDN6678, and BDN6641

BDN6677 Ear Microphone, Standard 95 dB (Black)

BDN6678 Ear Microphone, Standard 95 dB (Beige)

BDN6708 PTT Interface Module for use with BDN6677, BDN6678, and

BDN6641

NTN9815 NiCd High Capacity

NTN9816 NiCd High Capacity, Factory Mutual Intrinsically Safe

NTN9857 NiMH Ultra-High Capacity, Factory Mutual

Intrinsically Safe

NTN9858 NiMH Ultra-High Capacity

HLN6853 Belt Clip, 2 1/4 inch

NNTN4115 Carrying case, Bonded leather with 3” Swivel Belt Loop and T-

strap

NNTN4116 Carrying case, Bonded leather with 2.5” Swivel Belt Loop and T-

strap

NNTN4117 Carrying case, Bonded leather with 3” Belt Loop and T-strap

Accessories

63

Chargers

NOTE: Charge only the battery, not the radio with the battery

attached, with NTN1177, NTN1178, and NTN1179.

Charger Mounting

Kits

Enhanced and

Multi-Unit Line

Cords

NTN1177 Multi-Unit, Dual Rate, Rapid: 110 V

NTN1178 Multi-Unit, Dual Rate, Rapid: 240 V (3-prong UK plug)

NTN1179 Multi-Unit, Rapid, 240V (UK 13 MAP Plug)

NTN1667 Tri-Chemistry, 110V

NTN1668 Tri-Chemistry, 220V Single Unit Charger (2 Prong Euro Plug)

NTN1669 Tri-Chemistry, 230V

NTN1873 IMPRES™ Rapid, 110V Single Unit Charger

NTN1874 IMPRES™ Rapid, 220V Single Unit Charger

NTN1875 IMPRES™ Rapid, 240V Single Unit Charger

NTN7209 Single-Unit Dual Rate, Rapid w/o Cord

WPLN4111_R IMPRES™ Single-Unit Smart Charger, 110V

NLN7967 Wall Mount Kit for Multi-unit (6-pocket) Charger

NLN7968 Charger, Rack Mount for 6 Unit

NTN7373 110 V Interchangeable Line

NTN7374 220 V Interchangeable Line (2 prong Euro plug)

NTN7375 240 V Interchangeable Line (3 prong Euro plug)

Accessories

64

Notes

65

Glossary ➠

A/D Analog-to-Digital converter; converts an instantaneous dc voltage level to a corresponding digital

value.

ABACUS IC Custom integrated circuit providing a digital receiver IF backend.

CPS Customer Programming Software

CODEC Coder/Decoder IC for analog-to-digital and digital-to-analog conversion.

D/A Digital-to-Analog converter; converts a digital value to a corresponding dc voltage value.

DTMF Dual-Tone Multi-Frequency

DPL Digital Private-Line™

DSP Digital Signal Processor; microcontroller specifically tailored for signal processing

computations. In this case refers specifically to Motorola DSP56603.

Firmware Software or a software/hardware combination of computer programs and data, with a fixed logic

configuration stored in a read-only memory; information can not be altered or reprogrammed.

FGU Frequency Generation Unit

FLASHport™ A Motorola term that describes the ability of a radio to change memory. Every FLASHport radio

contains a FLASHport EEPROM memory chip that can be software written and rewritten to,

again and again.

Host Motorola HC12A4 microcontrol unit U204 (see MCU).

Host Port Parallel memory mapped interface consisting of eight registers in the DSP56603.

IC Integrated Circuit

IMBE Improved Multi-Band Excitation: a sub-band, voice encoding algorithm used in ASTRO digital

voice.

MCU MicroControl Unit

MDC Motorola Digital Communications

MISO Master In Slave Out; used by the slave device to send data to the master device

MOSI Master Out Slave In; used by the master device to send data to the slave device.

Open Architecture A controller configuration that utilizes a microprocessor with extended ROM and RAM.

PC Board Printed Circuit board

PCIC Power Control IC

PL Private-Line® tone squelch; a continuous sub-audible tone that is transmitted along with the

carrier.

PLL Phase-Locked Loop; a circuit in which an oscillator is kept in phase with a reference, usually

after passing through a frequency divider.

Glossary

66

PTT Push-To-Talk; the switch located on the left side of the radio which, when pressed, causes the

radio to transmit.

Registers Short-term data-storage circuits within the microcontrol unit or programmable logic IC.

Repeater Remote transmit/receive facility that re-transmits received signals in order to improve

communications coverage.

RESET Reset line; an input to the microcontroller that restarts execution.

RF PA Radio Frequency Power Amplifier

RPT/TA RePeaTer/Talk-Around

RX DATA Recovered digital data line.

Signal Qualifier Mode An operating mode whereby the radio is muted but still continues to analyze receive data to

determine RX signal type.

SCI IN Serial Communication Interface INput line

Softpot Software potentiometer; a computer-adjustable electronic attenuator.

Software Computer programs, procedures, rules, documentation, and data pertaining to the operation of a

system.

SPI Serial Peripheral Interface; how the microcontroller communicates to modules and ICs through

the CLOCK and DATA lines.

Squelch Muting of audio circuits when received signal levels fall below a pre-determined value.

SRAM Static-RAM chip used for volatile, program/data memory.

Standby Mode An operating mode whereby the radio is muted but still continues to monitor data.

System Select The act of selecting the desired operating system with the system-select switch (also, the name

given to this switch).

TOT Time-Out Timer; a timer that limits the length of a transmission.

TSOP Thin Small-Outline Package

UART Universal Asynchronous Receiver Transmitter.

µC Microcontrol unit (see MCU).

VCO Voltage-Controlled Oscillator; an oscillator whereby the frequency of oscillation can be varied by

changing a control voltage.

Vocoder VOice enCODER; the DSP-based system for digitally processing the analog signals, includes the

capabilities of performing voice compression algorithms or voice encoding.

VSWR Voltage Standing Wave Ratio

67

A

accessories

antennas ......................................................................61

batteries .......................................................................62

belt clips ......................................................................62

carry cases ..................................................................62

chargers .......................................................................63

multi-unit line cords ...................................................63

remote speaker microphones ......................................61

analog mode of operation .................................................6

antenna

attach the antenna .......................................................37

remove the antenna .....................................................37

ASTRO mode of operation ..............................................7

B

battery

attach the battery .........................................................38

remove the battery ......................................................38

belt clip

attach the belt clip .......................................................39

remove the belt clip ....................................................39

bit error rate ....................................................................29

C

chassis disassembly ........................................................45

cleaning external plastic surfaces .....................................3

control top and keypad test mode (display radio) ..........14

control top and keypad test mode (non-display radio) ...16

D

display radio test mode ..................................................12

E

exploded view, Model I .................................................33

exploded view, Model II ................................................34

exploded view, Model III ...............................................35

F

field programming equipment ........................................10

FLASHport .......................................................................2

front end filter alignment ...............................................28

G

glossary ..........................................................................65

H

handling precautions ........................................................4

M

model

chart, radio .................................................................. xv

model chart

ASTRO digital XTS 5000 .......................................... xv

Model numbering system ...............................................xiii

N

non-display radio test mode ...........................................15

notations used in this manual ...........................................1

O

operational error codes ...................................................58

P

power-up codes ..............................................................57

preventive maintenance ....................................................3

R

radio

model chart ................................................................. xv

radio alignment

front end filter .............................................................28

general ........................................................................19

reference oscillator .....................................................21

transmit deviation balance (compensation) ................25

transmit deviation limit ...............................................27

transmit power ............................................................23

radio alignment test setup ...............................................11

radio description ...............................................................2

radio disassembly

backup battery .............................................................46

chassis disassembly ....................................................45

display disassembly ....................................................49

front cover from chassis .............................................42

kepad and keypad option board ..................................47

PTT disassembly .........................................................51

required tools ..............................................................42

speaker, microphone, and universal connector flex ...50

radio information screen ................................................21

radio reassembly

backup battery .............................................................54

chassis and front cover ...............................................54

chassis assembly .........................................................54

keypad and keypad option board ..........................53, 54

PTT reassembly ..........................................................52

speaker, microphone, and universal connector flex ...53

recommended test equipment ...........................................9

reference oscillator alignment ........................................21

Index ➠

Index

68

remote speaker microphone adapter

attach the adapter ........................................................41

remove the adpater ......................................................41

required tools ..................................................................42

RF basic theory of operation ............................................7

RF test mode (display model) ........................................13

RF test mode (non-display radio) ...................................15

S

service aids .....................................................................10

Specifications for 700/800 MHz radios ........................ xiv

T

transmit deviation balance alignment .............................25

transmit deviation limit alignment .................................27

transmit power alignment ...............................................23

transmitter test pattern ....................................................31

U

universal connector cover

attach the connector cover ..........................................40

remove the connector cover ........................................40

V

VOCON basic theory of operation ...................................8

W

warranty ........................................................................... ix

warranty service ...............................................................x

REPLACEMENT PARTS ORDERING

ORDERING INFORMATION

MAIL ORDERS

Send written orders to the following addresses:

TELEPHONE ORDERS

United States and Canada Accessories and Aftermarket Division: Servicers Training (VHS Video Tapes):

Call: 1-800-422-4210 Call: 847-783-2522

1-800-826-1913 (For Federal Government Orders) 847-783-2523 (FAX)

1-847-538-8023 (International Orders)

FAX ORDERS

United States and Canada Accessories and Aftermarket Division: Federal Government Orders:

FAX: 847-538-8198 (Domestic) FAX: 410-712-4991

847-576-3023 (International) International: 410-712-6200

Parts ID: 847-538-8194

PARTS CUSTOMER SERVICE PRODUCT CUSTOMER SERVICE

When ordering replacement parts or equipment

information, the complete identification number should

be included. This applies to all components, kits, and

chassis. If the component part number is not known, the

order should include the number of the chassis or kit of

which it is a part, and sufficient description of the desired

component to identify it.

Crystal and channel element orders should specify the

crystal or channel element type number, crystal and

carrier frequency, and the model number in which the

part is used.

Replacement Parts/

Test Equipment/Manuals/

Crystal Service Items:

Motorola Inc.

United States and Canada Accessories

and Aftermarket Division

Attention: Order Processing

1313 E. Algonquin Road

Schaumburg, IL 60196

Federal Government Orders:

Motorola Inc.

United States and Canada Accessories

and Aftermarket Division

Attention: Order Processing

7230 Parkway Drive

Landover, MD 21076

International Orders:

Motorola Inc.

United States and Canada

Accessories and Aftermarket Division

Attention: International Order

Processing

1313 E. Algonquin Road

Schaumburg, IL 60196

United States and Canada Accessories and Aftermarket

Division:

Call: 1-800-422-4210

Parts Identification:

Call: 847-538-0021

Customer Response Center

(Sales and Service Assistance):

Call: 1-800-247-2346

FAX: 1-800-232-9272

Motorola, Inc.

8000 West Sunrise Boulevard

Ft. Lauderdale, Florida 33322

MOTOROLA and the Stylized M Logo are registered in the U.S. Patent and

Trademark Office. All other product or service names are the

property of their respective owners.

© Motorola, Inc. 2002, 2003

All rights reserved. Printed in U.S.A.

6881094C09-B